Toro 4014-D, 4000-D User Manual

Part No. 10176SL (Rev. A)
Service Manual
(Models 30448 and 30446)
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 (Model 30448) and 4010--D (Model 30446).
REFER TOTHEOPERATOR’SMANUALFOROPER­ATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. For reference, insert a copy of the Operator’sManualandParts Catalog for your machine into Chapter 2 of this service manual. Additional copies of the Operator’s Manual and Parts Catalog are avail­able on the internet at www.Toro.com.
TheToroCompany reservestheright tochange product specifications or this publication without notice.
R
4000--D & 4010--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 willgivegeneral informationabout the
correct operation, maintenance, service, testing or re­pair of the machine.
IMPORTANT: The IMPORTANT notice will give im­portantinstructionswhichmustbefollowed to pre­vent damage to systems or components on the machine.
Groundsmaster4000--D
E The Toro Company -- 2010, 2012
Groundsmaster4010--D
This page is intentionally blank.
Groundsmaster 4000--D/4010--D

Table Of Contents

Chapter 1 -- Safety
General Safety Instructions 1 -- 2..................
Jacking Instructions 1 -- 5.........................
Safety and Instruction Decals 1 -- 6................
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..............................
Service and Repairs 3 -- 4........................
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
V2403--M--T--E3B SERIES
Chapter 4 -- Hydraulic System
Specifications 4 -- 2..............................
General Information 4 -- 3........................
Hydraulic Schematic 4 -- 9........................
Hydraulic Flow Diagrams 4 -- 10...................
Special Tools 4 -- 26.............................
Troubleshooting 4 -- 30...........................
Testing 4 - - 36...................................
Adjustments 4 -- 70..............................
Service and Repairs 4 -- 72.......................
EATON MODEL 72400 SERVO CONTROLLED PIS-
TON PUMP REPAIRINFORMATION
EATONMODEL 74318 and 74348 PISTONMOTORS:
FIXED DISPLACEMENT, VALVE PLATE DESIGN REPAIR INFORMATION
Chapter 5 -- Electrical System
General Information 5 -- 2........................
Special Tools 5 -- 3..............................
Troubleshooting 5 -- 6............................
Adjustments 5 -- 17..............................
Electrical System Quick Checks 5 -- 18.............
Component Testing 5 -- 20........................
Service and Repairs 5 -- 47.......................
Chapter 6 -- Axles, Planetaries and Brakes
Specifications 6 -- 2..............................
General Information 6 -- 3........................
Service and Repairs 6 -- 4........................
Chapter 7 -- Chassis
General Information 7 -- 1........................
Service and Repairs 7 -- 2........................
Chapter 8 -- Cutting Decks
Specifications 8 -- 2..............................
General Information 8 -- 3........................
Troubleshooting 8 -- 4............................
Service and Repairs 8 -- 6........................
SafetyProduct Records
and Maintenance
Kubota
Diesel Engine
System
Hydraulic
System
Electrical
Groundsmaster 4000--D/4010--D
Axles, Planetaries
Chassis
Cutting
and Brakes
Decks
This page is intentionally blank.
Groundsmaster 4000--D/4010--D
Table Of Contents (Continued)
Chapter 9 -- Operator Cab
General Information 9 -- 2........................
Service and Repairs 9 -- 3........................
SANDEN SD COMPRESSOR SERVICE GUIDE
Chapter 10 -- Foldout Drawings
Hydraulic Schematic 10 -- 3.......................
Electrical Schematics 10 -- 4......................
Wire Harness Drawings 10 -- 9....................
Cab
OperatorFoldout
Drawings
Groundsmaster 4000--D/4010--D
This page is intentionally blank.
Groundsmaster 4000--D/4010--D
Chapter 1
Safety

Table of Contents

GENERAL SAFETY INSTRUCTIONS 2............
Before Operating 2............................
While Operating 3.............................
Maintenance and Service 4....................
JACKING INSTRUCTIONS 5.....................
SAFETY AND INSTRUCTION DECALS 6..........
Safety
Groundsmaster 4000--D/4010--D Page 1 -- 1 Safety

General Safety Instructions

TheGroundsmaster4000-Dand4010--Daretestedand certified by Toro for compliance with existing safety standards and specifications. 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 ofthemachinecan resultin injury or death. Toreducethepotentialforinjury or death, comply with the following safety instructions.

Before Operating

WARNING
To reduce the potential for injury or death, comply with the following safety instructions.
1. Review and understand the contents of the Opera­tor’s Manual and Operator’s DVD before starting and operatingthe vehicle. Become familiar with the controls and know how to stop the vehicle and engine quickly. AdditionalcopiesoftheOperator’sManualareavailable on the internet at www.Toro.com.
2. Keep all shields, safety devices and decals in place. Ifa shield, safety device or decal isdefective,illegibleor damaged, repair or replace it before operating the ma­chine.Also tighten anyloosenuts,bolts or screws toen­sure machine is in safe operating condition.
3. Assure interlock switches are adjusted correctly so engine cannot be started unless traction pedal is in NEUTRAL and cutting decks are DISENGAGED.
4. Since diesel fuel is highly flammable, handle it care­fully:
A. Use an approved fuel container. B. Donotremovefuel tank capwhileengine ishotor
running. C. Do not smoke while handling fuel. D. Fillfueltankoutdoors and onlytowithinan inch of
the top of the tank, not the filler neck. Do not overfill. E. Wipe up any spilled fuel.
Groundsmaster 4000--D/4010--DPage 1 -- 2Safety

While Operating

1. Sit on the seat when starting and operating the ma­chine.
2. Before starting the engine:
A. Apply the parking brake. B. Make sure traction pedal is in neutral and the
PTO switch is OFF (disengaged). C. Afterengineis started,releaseparking brakeand
keepfootofftraction 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 ade­quate ventilation. Exhaust fumes are hazardous and could possibly be deadly.
4. Do not touch engine, muffler or exhaust pipe while engineisrunningorsoonafteritisstopped.Theseareas could be hot enough to cause burns.
5. Before getting off the seat: A. Ensure that traction pedal is in neutral. B. Apply the parking brake.
Safety
C. Disengage cutting decks and wait for blades to stop.
D. Stop engine and remove key from switch. E. Toro recommends that anytime the machine is
parked(shortor long term), the cutting decksshould be lowered to the ground. This relieves hydraulic pressurefrom the lift circuit and eliminates the risk of the cutting decks unexpectedly lowering to the ground.
F. Do notpark ons lopes unlesswheelsarechocked or blocked.
Groundsmaster 4000--D/4010--D Page 1 -- 3 Safety

Maintenance and Service

1. Before servicing or making adjustments, lower decks, stop engine, apply parking brake and remove key from the ignition 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 wherethereisanopenflame,suchasnearawaterheat­er or furnace.
4. Make sure all hydraulic connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system.
5. Keepbodyandhandsawayfrompinholeleaksinhy­drauliclinesthateject high pressure 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 mustbe 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 re­lievedbyloweringcutting decks to the ground andstop­ping engine.
7. If major repairs areever needed orassistance 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. Ifenginemust be running to perform maintenanceor an adjustment, keep hands, feet, clothing and other parts of the body away from cutting decks and other moving parts. Keep bystanders away.
10.Do not overspeed the engine by changing governor setting.Toassuresafety andaccuracy,checkmaximum engine speed.
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,temporarilyconnectthebattery.Reconnect positive cable first and negative cable last.
13.Battery acid is poisonous and can cause burns. Avoidcontact 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 tothesafety standards for riding mowers. Toassure op­timumperformance and continuedsafetycertificationof the machine, use genuine Toro replacement parts and accessories.Replacementparts andaccessoriesmade by other manufacturers may result in non-conformance with the safety standards and the warranty may be voided.
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 suchasaconcrete floor.Priortoraising themachine,re­move any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use appropriate jack stands to support the raised machine. If the machine is not properly sup­ported by jack stands, the machine may move or fall, whichmay resultinpersonal injury(seeJacking Instruc­tions in this chapter).
17.When welding on machine, disconnect all battery cables to prevent damage to machine electronic equip­ment. Disconnect negative battery cable first and posi­tivecablelast.Also,disconnectwire harness connector fromboth of the TEC controllers and disconnect the ter­minal connector from the alternator. Attach welder ground cable no more than two (2) feet (0.61 meters) from the welding location.
11.Shut engine off before checking or adding oil to the crankcase.
Groundsmaster 4000--D/4010--DPage 1 -- 4Safety

Jacking Instructions

CAUTION
When changing attachments, tires or perform­ing other service, use correct jacks and sup­ports. 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 themachine.Always chockorblockwheels.Use jackstands to support the raised machine.If the machine is not properly supported by 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. Positionjack securely under the frame,justtothein­side of the front tire. Jack front wheel off the ground.
2
1. Front jacking point 2. Front tire
1
Figure 1
1
Safety
2
3. Once the machine is raised, position jack stand un­der the frame as close to the wheel 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. Once the machine is raised, use jack stands under the axle to support the machine.
2
1. Rear axle jacking point 2. Rear tire
1
Figure 2
2
Groundsmaster 4000--D/4010--D Page 1 -- 5 Safety

Safety and Instruction Decals

Numerous safety and instruction decals are affixed to your Groundsmaster machine. If any decal becomes il­legibleor damaged,installanew decal.Decalpartnum­bers are listed in your Parts Catalog.
Groundsmaster 4000--D/4010--DPage 1 -- 6Safety
Product Records and Maintenance

Table of Contents

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.......................
Using a Torque Wrench with an Offset Wrench 3.. Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Inch Series) 4...............
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Metric) 5....................
Other Torque Specifications 6..................
Conversion Factors 6..........................
Chapter 2

Product Records

and Maintenance
Product Records
Insert Operator’s Manuals and Parts Catalogs for your Groundsmaster at the end of this chapter. Additionally, if any optional equipment or accessories have been installedto your machine, insert the Installation Instruc­tions, Operator’s Manuals and Parts Catalogs for those options at the end of this chapter.

Maintenance

Maintenanceprocedures andrecommendedservice in­tervalsforyourGroundsmasterarecoveredintheOper­ator’sManual.Refertothatpublicationwhenperforming regular equipment maintenance.
Groundsmaster 4000--D/4010--D Page 2 -- 1 Product Records and Maintenance

Equivalents and Conversions

0.09375
Groundsmaster 4000--D/4010--DPage 2 -- 2Product Records and Maintenance

Torque Specifications

Recommended fastener torque values are listed in the followingtables.Forcriticalapplications,as determined byToro,eitherthe recommended torque or atorquethat 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 toall fasteners which donot have a specificrequirement 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 (e.g. Nylock nut), hardness of the surface underneath thefastener’sheadorsimilarcondition whichaffectsthe installation.

Fastener Identification

Asnoted inthefollowingtables,torquevaluesshouldbe 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. Measurethe 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

Using a Torque Wrench with an Offset Wrench

Useofanoffsetwrench(e.g.crowfootwrench)willaffect torquewrench calibration due to theeffectivechangeof torquewrench length. When using a torque wrench with an offset wrench, multiply the listed torque recommen­dation by the calculated torque conversion factor (Fig.
3) to determine proper tightening torque. Tightening torque when using a torque wrench with an offset wrench will be lower than the listed torque recommen­dation.
Example: The measured effective length of the torque wrench (distance from the center of the handle to the center of the square drive) is 18”.
Themeasuredeffectivelengthofthetorquewrenchwith the offset wrench installed (distance from the center of the handle to the center of the offset wrench) is 19”.
Class 8.8 Class 10.9
Metric Bolts and Screws
Figure 2
If the listed torque recommendation for a fastener is from 76 to 94 ft--lb, the proper torque when using this torque wrench with an offset wrench would be from 72 to 89 ft--lb.
(effective length of
torque wrench)
A
B
(effective length of torque
wrench + offset wrench)
TORQUE CONVERSION FACTOR = A / B
Torque wrenchOffset wrench
The calculated torque conversion factor for this torque wrenchwiththisoffsetwrenchwouldbe 18 / 19 = 0.947.
Groundsmaster 4000--D/4010--D Page 2 -- 3 Product Records and Maintenance
Figure 3

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)

Thread Size
# 6 -- 32 UNC
# 6 -- 40 UNF
# 8 -- 32 UNC
# 8 -- 36 UNF
#10--24UNC
#10--32UNF
1/4 -- 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1130+ 113 140 + 15 1582+ 169
1/4 -- 28 UNF 53 + 7 65 + 10 734 + 113 115 + 12 1299 + 136 160+ 17 1808 + 192
5/16 -- 18 UNC 115 + 15 105 + 15 1186 + 169 200 + 25 2260+ 282 300+ 30 3390 + 339
5/16 -- 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2542+ 282 325 + 33 3672 + 373
3/8 -- 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 5 58 + 7
Grade 1, 5 &
8withThin
Height Nuts
in--lb in--lb N--cm in--lb N--cm in--lb N--cm
10 + 2 13 + 2 147 + 23
13 + 2 25 + 5 282 + 30
18 + 2 30 + 5 339 + 56
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 + 2 169 + 23 23 + 3 262 + 34
17 + 2 192 + 23 25 + 3 282 + 34
29 + 3 328 + 34 41 + 5 463 + 56
31 + 4 350 + 45 43 + 5 486 + 56
42 + 5 475 + 56 60 + 6 678 + 68
48 + 5 542 + 56 68 + 7 768 + 79
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 + 4 47 + 5 50 + 6 68 + 8
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 + 6 75 + 8 77 + 8 104 + 11
1/2 -- 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 11 142 + 15
1/2 -- 20 UNF 32 + 4 53 + 7 72 + 9 85 + 9 115 + 12 120 + 12 163 + 16
5/8 -- 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 21 285 + 28
5/8 -- 18 UNF 75 + 10 95 + 15 129 + 20 170 + 18 230 + 24 240 + 24 325 + 33
3/4 -- 10 UNC 93 + 12 140 + 20 190 + 27 265 + 27 359 + 37 375 + 38 508 + 52
3/4 -- 16 UNF 115 + 15 165 + 25 224 + 34 300 + 30 407 + 41 420 + 43 569 + 58
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 + 48 644 + 65 667 + 66 904 + 89
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 engine oil 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 mini­mumproof load specified in SAE J429. The tolerance is approximately +
10% of the nominal torque value. Thin
height nuts include jam nuts. 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.
Groundsmaster 4000--D/4010--DPage 2 -- 4Product Records and Maintenance

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)

Class 8.8 Bolts, Screws and Studs with
Thread Size Regular Height Nuts
(Class 8 or Stronger Nuts)
Class 10.9 Bolts, Screws and Studs with
Regular Height Nuts
(Class 10 or Stronger Nuts)
M5 X 0.8 57 + 6in--lb 644 + 68 N--cm 78 + 8in--lb 881 + 90 N--cm
M6 X 1.0 96 + 10 in--lb 1085 + 113 N- -cm 133 + 14 in--lb 1503 + 158 N--cm M8 X 1.25 19 + 2ft--lb 26 + 3N--m 28 + 3ft--lb 38 + 4N--m M10 X 1.5 38 + 4ft--lb 52 + 5N--m 54 + 6ft--lb 73 + 8N--m
M12 X 1.75 66 + 7ft--lb 90 + 10 N--m 93 + 10 ft--lb 126 + 14 N--m
M16 X 2.0 166 + 17 ft--lb 225 + 23 N--m 229 + 23 ft--lb 310 + 31 N--m M20 X 2.5 325 + 33 ft--lb 440 + 45 N--m 450 + 46 ft--lb 610 + 62 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 engine oil or thread sealant such as Loctite.
NOTE: The nominal torque values listed above are based on 75% of the minimum proof load specified in SAEJ1199.Thetoleranceisapproximately+ nominal torque value.
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.
10%ofthe
Product Records
and Maintenance
Groundsmaster 4000--D/4010--D Page 2 -- 5 Product Records and Maintenance

Other Torque Specifications

*
SAE Grade 8 Steel Set Screws
Recommended Torque
Thread Size
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 + 3ft--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 + 5in--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
Size
No. 6 18 20 20 + 5in--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
Baseline Torque
No. 8 -- 32 UNC 30 + 5in--lb
No. 10 -- 24 UNC 38 + 7in--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 + 5in--lb No. 10 12 16 38 + 7in--lb No. 12 11 14 85 + 15 in--lb
*Holesize,materialstrength,materialthicknessandfin­ish must be considered when determining specific torquevalues. Alltorquevalues arebasedonnon--lubri­cated fasteners.
Groundsmaster 4000--D/4010--DPage 2 -- 6Product Records and Maintenance

Table of Contents

SPECIFICATIONS 2.............................
GENERAL INFORMATION 3.....................
Operator’s Manual 3..........................
Stopping the Engine 3.........................
SERVICE AND REPAIRS 4......................
Air Filter System 4............................
Exhaust System 6............................
Fuel System 8................................
Check Fuel Lines and Connections 9...........
Empty and Clean Fuel Tank 9.................
Fuel Tank Removal 9........................
Fuel Tank Installation 9.......................
Radiator 10..................................
Engine 12....................................
Engine Removal 13..........................
Engine Installation 15........................
Spring Coupler 18.............................
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
03--M--E3B SERIES
Chapter 3
Kubota Diesel Engine
Kubota
Diesel Engine
Groundsmaster 4000--D/4010--D Page 3 -- 1 Kubota Diesel Engine

Specifications

Item Description
Make / Designation Kubota Model V2403--M--T--E3B: 4--Cycle, 4 Cylinder,
Bore 3.43 in (87.0 mm)
Stroke 4.031 in (102.4 mm)
Total Displacement 148.5 in3(2434 cc)
Firing Order 1 (closest to gear case end) -- 3 -- 4 (closest to flywheel end) -- 2
Combustion Chamber Spherical Type (E--TVCS)
Compression Ratio 23.0:1
Direction of Rotation Counterclockwise (viewed from flywheel)
Fuel Diesel or Biodiesel (up to B20) Fuel with Low or
Fuel Capacity 19 U.S. gallons (72 liters)
Fuel Injection Pump Denso PFR 4M Type Mini Pump
Injection Nozzle Denso OPD Mini Nozzle
Water Cooled, Turbocharged, Diesel Engine
Ultra Low Sulfur Content
Governor Centrifugal Mechanical
Low Idle (no load) 1425 + 50 RPM
High Idle (no load) 2870 + 50/--120 RPM
Engine Oil API CH--4, CI--4 or higher
Engine Oil Viscosity See Operator’s Manual
Crankcase Oil Capacity 10 U.S. quarts (9.5 liters) with Filter
Oil Pump Trochoid Type
Coolant Capacity
Groundsmaster 4000--D 13 U.S. quarts (12.3 liters) Groundsmaster 4010--D 17 U.S. quarts (16.1 liters)
Starter 12 VDC, 2.0 kW
Alternator/Regulator 12 VDC
Groundsmaster 4000--D 40 amp Groundsmaster 4010--D 90 amp
Engine Dry Weight 419 U.S. pounds (190 kg)
Groundsmaster 4000--D/4010--DPage 3 -- 2Kubota Diesel Engine

General Information

ThisChapter gives informationaboutspecificationsand repair of the diesel engine used in Groundsmaster 4000--D and 4010--D machines.
Generalmaintenance procedures are described inyour Operator’sManual.Informationonenginetroubleshoot­ing,testing, disassembly and reassemblyis identifiedin the Kubota Workshop Manual, Diesel Engine, 03--M--E3B that is included at the end of this section.
Most repairs and adjustments require tools which are commonly available in many service shops. Special

Operator’s Manual

The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervalsfor yourGroundsmastermachine.Refer tothat publicationfor additional informationwhenservicingthe machine.

Stopping the Engine

tools are described in the Kubota Workshop Manual, Diesel Engine, 03--M--E3B. 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 partslistisavailable,bepreparedtoprovideyourdistrib­utor with the Toro model and serial number of your ma­chine.
Kubota
Diesel Engine
IMPORTANT: Before stopping the engine after mowing or full load operation, cool the turbo-char­ger by allowing the engine to run at low idle speed for five (5) minutes. Failure to do so may lead to tur­bo-charger trouble.
Groundsmaster 4000--D/4010--D Page 3 -- 3 Kubota Diesel Engine

Service and Repairs

Air Filter System

RIGHT
7
FRONT
11
10
18
1. Air cleaner hose
2. Hose clamp
3. Air cleaner assembly
4. Indicator
5. Air cleaner strap
6. Lock nut (2 used)
Figure 1
7. Hose clamp
8. Air cleaner hose
9. Hose clamp
10. Cap screw (2 used)
11. Flat washer (4 used)
12. Spring (2 used)
11
5
1
9
12 to 15 in--lb
(1.4 to 1.6 N--m)
12
6
13
14
4
15
8
2
16
17
3
13. Flat washer (2 used)
14. Cap screw (2 used)
15. Adapter
16. Lock nut (2 used)
17. Flat washer (2 used)
18. Overflow bracket
VACUATOR DIRECTION
Groundsmaster 4000--D/4010--DPage 3 -- 4Kubota Diesel Engine
Removal (Fig. 1)
1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch.
2. Raise and support hood.
3. Remove air cleaner components as needed using Figure 1 as a guide.
Installation (Fig. 1) IMPORTANT: Any leaks in the air filter system will
causeserious engine damage.Make surethat allair cleaner components are in good condition and are properly secured during assembly.
1. Assemble air cleaner system using Figure 1 as a guide.
A. Ifservice indicator (item 4) and adapter (item 15) wereremovedfromaircleanerhousing,applythread sealant to adapter threads before installing adapter and indicator to housing. Install adapter so that groovesinadapter hexandadapterfilter elementare installed toward serviceindicator (Fig. 3). Torquein­dicator from 12 to 15 in--lb (1.4 to 1.6 N--m).
4
5
1. Air cleaner housing
2. Safety filter element
3. Air filter element
2
Figure 2
3
4. Air cleaner cover
5. Vacuator valve
3
1
2
Kubota
Diesel Engine
B. When securing air cleaner in air cleaner strap, tighten cap screws (item 14) only enough to prevent air cleaner from rotating in strap.
2. Wheninstallingair cleaner hose (item 1) betweenair cleaner and turbo--charger (Fig. 4):
A. Make sure that hose does not contact engine valve cover. To ensure clearance, move and/or ro­tate air cleaner body in air cleaner strap.
B. Position hose to allow maximum clearance be­tween air cleaner hose and muffler bracket.
3. Lower and secure hood.
1
1. Air cleaner assembly
2. Service indicator
4
3
1. Air cleaner hose
2. Muffler bracket
Figure 3
3. Adapter
1
2
Figure 4
3. Air cleaner strap
4. Air cleaner slots
Groundsmaster 4000--D/4010--D Page 3 -- 5 Kubota Diesel Engine

Exhaust System

16 to 22 ft--lb
(21to29N--m)
RIGHT
FRONT
16 to 22 ft--lb
(21to29N--m)
3
7
8
14
4
5
7
8
9
6
13
8
10
16 to 22 ft--lb
(21to29N--m)
11
12
1
16 to 22 ft--lb
(21to29N--m)
11
2
15
16
13 ft--lb
(17.6 N--m)
8
6
1. Muffler
2. Muffler bracket
3. Exhaust pipe
4. Flange head screw (4 used)
5. Exhaust gasket
6. Lock nut (2 used)
Figure 5
7. Cap screw (2 used)
8. Flat washer (4 used)
9. Spacer (2 used)
10. Rubber hanger
11. Flange nut (4 used)
12. Flange head screw (2 used)
13. Engine mount
14. Muffler clamp
15. Exhaust mount
16. Flange head screw (2 used)
Groundsmaster 4000--D/4010--DPage 3 -- 6Kubota Diesel Engine
Removal (Fig. 5)
CAUTION
The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and ex­haust system to c ool before working on the muf­fler.
1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch.
2. Raise and support hood.
3. Remove exhaust system components from the en­gine as necessary using Figure 5 as a guide.
Installation (Fig. 5) 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: Make sure muffler flange and exhaust manifold
sealing surfaces are free of debris or damage that may prevent a tight seal.
C
E
B
D
A
Figure 6
Kubota
Diesel Engine
1. Install new exhaust gasket if original gasket is dam­aged or torn.
IMPORTANT: Failure to follow the suggested muf­fler fastener sequencemay result in prematuremuf­fler failure.
2. Installexhaustsystemcomponentsto the engine us­ing Figure 5 as a guide. Hand tighten exhaust system fastenersand thentorqueinthesequence showninFig. 6 as follows:
A. Torque lock nuts used on rubber hanger cap screws from 16 to 22 ft--lb (21 to 29 N--m).
B. Torque flange head screws that secure muffler flange to engine from 16 to 22 ft--lb (21 to 29 N--m).
C. Torque flange nuts that secure muffler t o muffler bracket from 16 to 22 ft--lb (21 to 29 N--m).
D. T orqueflangenuts that securemuffler bracketto engine from 16 to 22 ft --lb (21 to 29 N-- m).
E. Torqueflange screws thatsecure exhaust m ount to engine to 1 3 f t -- l b ( 1 7 . 6 N -- m ) .
3. Tailpipeshouldhaveequalclearancebetweenframe and engine after installation.
4. Lower and secure hood. Rev. AGroundsmaster 4000--D/4010--D Page 3 -- 7 Kubota Diesel Engine

Fuel System

6
4
37
23
26
25 24
39
40
27
38
29
30
31
28
33
36
35
34
29
3
2
22
1
20
14
RIGHT
18
FRONT
1. Fuel tank
2. Fuel tank bracket
3. ROPS assembly
4. Washer head screw (3 used)
5. Tank support assembly
6. Insulated clip (3 used)
7. Flange nut (6 used)
8. Cap screw (4 used)
9. Flat washer (4 used)
10. Cap screw (4 used)
11. Carriage screw (2 used)
12. Washer (2 used)
13. Battery strap
14. Battery
17
21
16
15
19
7
12
11
13
60 to 80 in--lb
(7 to 9 N--m)
Figure 7
15. Retaining ring (2 used)
16. Battery cover
17. Flat washer (2 used)
18. Knob (2 used)
19. Battery plate
20. Negative cable
21. Positive cable
22. Carriage screw
23. Gasket
24. Bushing (3 used)
25. Stand pipe
26. Fuel sender
27. Lock washer (5 used)
32
5
7
8
9
10
135 to 165 ft--lb
(183 to 223 N--m)
28. Phillips head screw (5 used)
29. Vent hose
30. Hose clamp
31. Elbow fitting (2 used)
32. Fuel cap
33. Locking flange nut (2 used)
34. Speed nut (4 used)
35. Tank cover (2 used)
36. Phillips head screw (4 used)
37. Vent tube
38. Overflow hose
39. Hose clamp
40. Fuel supply hose
Groundsmaster 4000--D/4010--DPage 3 -- 8Kubota Diesel Engine
Fuel Tank Installation (Fig. 7)
DANGER
Becausedieselfuel ishighly 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
Checkfuel lines and connectionsperiodicallyasrecom­mendedinthe Operator’sManual.Check lines for dete­rioration, damage, leaking or loose connections. Replace hoses, clamps and connections as necessary.
Empty and Clean Fuel Tank
Empty and clean the fuel tank periodically as recom­mended in the Operator’s Manual. Also, empty and clean the fuel tank if the fuel system becomes contami­nated or if the machine is to be stored for an extended period.
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
decks, stop engine, apply parking brake and remove key from the ignition switch.
2. Raise and support operator seat and hood.
1. Install fuel tank using Figure 7 as a guide. A. Torque two(2)flange nuts(item7) thatsecurethe
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 supply hose to the standpipe and vent
andoverflow hoses to theelbow fittings (Fig. 8). Secure hoses with clamps.
4. Connect wire harness connections to the fuel send-
er.
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--overgrease to the wire terminal con­nections.
Kubota
Diesel Engine
CAUTION
Connecting battery cables to the wrong battery post could result in personal injury and/or dam­age to the electrical system.
5. Positionbatteryinmachine.Connectpositivebattery
cable first and then negative battery cable. Install bat­tery strap and cover.
6. Lower and secure operator seat and hood.
7. Fill fuel tank.
3. Remove battery cover and strap. Disconnect nega­tive battery cable first and then positive battery cable. Remove battery from machine.
4. Useafueltransferpump toremove fuel from the fuel tank and into a suitable container.
5. Disconnect wire harness connections from the fuel sender (item 26).
6. Disconnect fuel supply hose from standpipe and ventandoverflowhoses fromelbowfittingsintop oftank (Fig. 8).
7. Remove phillips head screws that secure two (2) tank covers (item 35) to ROPS assembly.Remove tank covers.
8. Remove fuel tank using Figure 7 as a guide.
Groundsmaster 4000--D/4010--D Page 3 -- 9 Kubota Diesel Engine
1
1. Fuel supply hose
2. Vent hose
4
Figure 8
3. Overflow hose
4. Fuel sender
3
2

Radiator

61
32
13
RIGHT
FRONT
14
35
34
48
38
20
19
28
22
23
24
25
21
49
25
26
45 54
12
27
7
46
18
16
28
51
53
17
62
1
52
9
50
8
6
41
30
59
4
5
55
37
56
11
29
58
49 10 60
57
42
43
15
41
44
45
47
2
31
33
28
58
3
1. Radiator cap
2. Foam strip (2 used)
3. Foam strip (2 used)
4. Lower radiator hose
5. Upper radiator hose
6. Clamp (4 used)
7. Lower radiator shroud
8. Temperature sender
9. Radiator
10. Hose clamp (3 used)
11. Hose(2used)
12. Screw (4 used)
13. Rubber grommet
14. Flange nut (4 used)
15. Retaining ring (2 used)
16. Knob (2 used)
17. Bulb seal
18. Top radiator support
19. Retaining ring (2 used)
20. Oil cooler bracket
21. Oil cooler
3639
40
Figure 9
22. Carriage screw (2 used)
o
23. 90
hydraulic fitting (2 used)
24. Cap screw (6 used)
25. Lock washer (6 used)
26. Oil cooler mount plate (2 used)
27. Upper radiator shroud
28. Flange nut (10 used)
29. Foam plug (2 used)
30. Lock nut (6 used)
31. Foam strip
32. Base bracket
33. Flange head screw (6 used)
34. Bulb seal (2 used)
35. Grommet (2 used)
36. Cover
37. Flange head screw (4 used)
38. Plate (2 used)
39. Flat washer (2 used)
40. Knob (2 used)
41. Cap screw (6 used)
42. Cable tie
43. Coolant reservoir
44. Tank bracket
45. Flat washer (10 used)
46. Foam pad
47. Cap screw (7 used)
48. Foam seal
49. Cap screw (3 used)
50. LH radiator support
51. RH radiator support
52. Flange nut (6 used)
53. Cap screw (6 used)
54. Fan motor bracket
55. Grommet (2 used)
56. Grommet
57. Harness clip
58. R--clamp (2 used)
59. Foam pad
60. Reservoir cap
61. Air cleaner hose
62. Plug
Groundsmaster 4000--D/4010--DPage 3 -- 10Kubota Diesel Engine
Removal (Fig. 9)
Installation (Fig. 9)
1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch.
2. Open and support hood.
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 upper and lower radiator hoses from the radiator.
5. Remove air cleaner hose (item 61).
6. Disconnect reservoir hose from the vent tube near the radiator cap.
1. Remove all plugs placed during the removal proce­dure.
2. Carefully position radiator to the support frame. Se­cure radiator to the support frame with cap screws and flange nuts.
3. Iftemperaturesender(item8)wasremovedfromra­diator,install new O--ring on sender and thread sender into radiator. Torque sender from 9to11ft--lb(12.3to
14.9 N--m). Reconnect wire harness connector to sen­der.
4. Positionlower radiator shroud andfanmotorbracket assembly to the radiator.
5. Secure fan motor bracket to radiator with six (6) flangehead screws and flangenuts.Positionbracketas far as possible from radiator to maximize distance be­tween radiator and fan motor location.
6. Position upper radiator shroud to lower radiator shroud to radiator. Secure shrouds with removed fas­teners.
7. Attach radiator shroud assembly to the radiator with cap screws and flat washers. Make sure that clearance between shroud and cooling fan is at least 0.180” (4.6 mm) at all points.
Kubota
Diesel Engine
7. Detach upper radiator shroud from the radiator and lower radiator shroud. Remove upper shroud from ma­chine.
8. Removefastenersthatsecurelower radiator shroud to radiator.
9. Remove six (6) flange head screws and flange nuts that secure fan motor bracket to radiator.
10.Position lowerradiatorshroudand fan motorbracket assembly away from radiator.
11.Disconnect wire harness connector from tempera­ture sender (item 8).
12.Removecapscrewsand flangenutssecuringthe ra­diator to the support frame. Carefully pull radiator from the machine.
13.Plug all radiator and hose openings to prevent con­tamination.
8. Connect reservoir hose to the vent tube near the ra­diator cap.
9. Connectupper andlowerradiator hosestothe radia­tor.
10.Reinstall air cleaner hose (item 61).
11.Make sure radiator drain is closed. Fill radiator with coolant.
12.Close and secure hood.
Groundsmaster 4000--D/4010--D Page 3 -- 11 Kubota Diesel Engine

Engine

21
23
22
RIGHT
FRONT
25
24
28
27
13
12
26
1
2
3
4
5
6
11
7
13
20
19
28 to 32 ft--lb
(38to43N--m)
1. Engine
2. Cap screw (4 used)
3. LH engine mount
4. Lock washer
5. Cap screw
6. Lock washer (5 used)
7. Cap screw (5 used)
8. Engine support (4 used)
9. Flange nut (12 used)
10. Rebound washer (4 used)
18
13
16
17
28 to 32 ft--lb
(38to43N--m)
11. Cap screw (8 used)
12. Spring coupler
13. Washer (14 used)
14. Cap screw (6 used)
15. Flywheel plate
16. Cap screw (4 used)
17. Cap screw (2 used)
18. Lock washer (2 used)
19. LH engine mount
14
15
Figure 10
29 to 33 ft--lb
(40to44N--m)
9
10
9
Loctite #242
20. Cap screw (4 used)
21. RH engine mount
22. Cap screw (PTO manifold)
23. Lock washer
24. Ground cable
25. Cap screw
26. Lock washer
27. RH engine mount
28. Ground harness
8
Groundsmaster 4000--D/4010--DPage 3 -- 12Kubota Diesel Engine
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