Toro 4100-D User Manual
Part No. 08162SL (Rev. A)
Service Manual
(Model 30413)
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 4100--D (Model 30413).
REFER TOTHEOPERATOR’S MANUALFOROPERATING, 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
4100--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 im portantinstructionswhichmustbefollowed to prevent damage to systems or components on the
machine.
E The Toro Company -- 2008, 2012
This page is intentionally blank.
Groundsmaster 4100--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..............................
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 -- 8........................
Hydraulic Flow Diagrams 4 -- 10...................
Special Tools 4 -- 26.............................
Troubleshooting 4 -- 28...........................
Testing 4 - - 31...................................
Adjustments 4 -- 60..............................
Service and Repairs 4 -- 61.......................
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 -- 5............................
Electrical System Quick Checks 5 -- 8..............
Adjustments 5 -- 9...............................
Component Testing 5 -- 11........................
Service and Repairs 5 -- 37.......................
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 Deck
Specifications 8 -- 2..............................
General Information 8 -- 3........................
Troubleshooting 8 -- 4............................
Service and Repairs 8 -- 6........................
Chapter 9 -- Foldout Drawings
Hydraulic Schematic 9 -- 3........................
Electrical Schematic 9 -- 4........................
Circuit Diagrams 9 -- 6...........................
Wire Harness Drawings 9 -- 12....................
SafetyProduct Records
and Maintenance
Kubota
Diesel Engine
System
Hydraulic
System
Electrical
Axles, Planetaries
and Brakes
Groundsmaster 4100--D
Cutting Deck Chassis
Foldout
Drawings
This page is intentionally blank.
Groundsmaster 4100--D
Table of Contents
GENERAL SAFETY INSTRUCTIONS 2............
Before Operating 2............................
While Operating 2.............................
Maintenance and Service 3....................
JACKING INSTRUCTIONS 4.....................
Jacking the Front End 4........................
Jacking the Rear End 4........................
SAFETY AND INSTRUCTION DECALS 5..........
Chapter 1
Safety
Safety
Groundsmaster 4100--D
Page 1 -- 1
Safety
General Safety Instructions
TheGROUNDSMASTER 4100-D was tested and 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. To reduce thepotentialforinjury
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. Keepall shields, safetydevices 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 deck is DISENGAGED.
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 linkage until machine does not move when
traction pedal is released.
4. Sincediesel 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.
5. Before getting off the seat:
A. Ensure that traction pedal is in neutral.
B. Apply parking brake.
C. Disengage cutting deck 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 deck should
be lowered to the ground. This relieves pressure
from the lift circuit and eliminates the risk of the cutting deck unexpectedly lowering to the ground.
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.
Safety
Page 1 -- 2
F. Donotparkonslopesunlesswheels arechocked
or blocked.
Groundsmaster 4100--D
Maintenance and Service
1. Beforeservicing ormakingadjustments, lower deck,
stop engine, apply parking brake and remove key from
the switch.
2. Makesure machine isin 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. Makesureall hydraulic line connectors are tight and
all hydraulic hoses and lines are in good condition before applying pressure to the system.
5. Keepbodyandhandsaway frompin holeleaks inhydrauliclinesthateject 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. Beforedisconnecting or performing any work on the
hydraulic system, all pressure in system must be relieved by stopping engine and lowering cutting deck to
the ground.
10.Do not overspeed the engine by changing governor
setting.Toassuresafety andaccuracy,checkmaximum
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,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.
Safety
7. Ifmajor repairs are everneeded 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. Ifengine must berunningtoperformmaintenanceor
an adjustment, keep hands, feet, clothing and other
partsof the bodyawayfromcutting deck and othermoving 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
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).
Groundsmaster 4100--D
Page 1 -- 3
Safety
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 securelyunder the frame, just to the inside of the front tire. Jack front wheel off the ground.
1
2
Figure 1
1. Frame jacking point 2. Front tire
1
2
3. Once the machine is raised, position suitable jack
standunder the frame as close to the wheel aspossible
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. Oncethe machine israised,usesuitablejack stands
under the rear axle to support the machine.
2
1. Rear axle jacking point 2. Rear tire
1
Figure 2
2
Safety
Page 1 -- 4
Groundsmaster 4100--D
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
theGroundsmaster4100--D.If anydecalbecomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog.
Safety
Groundsmaster 4100--D
Page 1 -- 5
Safety
This page is intentionally blank.
Safety
Page 1 -- 6
Groundsmaster 4100--D
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 Manual and Parts Catalog f or your
Groundsmaster4100--Datthe endofthis chapter.Refer
to Operator’s Manual for recommended maintenance
intervals. Additionally, insert Installation Instructions,
Operator’sManuals and Parts Catalogs for any accessories that have been installed on your Groundsmaster
at the end of this section.
Maintenance
Maintenanceprocedures and recommended service intervals for the Groundsmaster 4100--D are covered in
the Operator’s Manual. Refer to that publication when
performing regular equipment maintenance. Several
maintenanceprocedureshave break--inintervalsidentifiedin the Operator’sManual.Referto the Engine Operator’s Manual for additional engine specific
maintenance procedures.
Groundsmaster 4100--D Page 2 -- 1 Product Records and Maintenance
Rev. A
Equivalents and Conversions
0.09375
Groundsmaster 4100--DPage 2 -- 2Product Records and Maintenance
Torque Specifications
Recommended fastener torque values are listed in the
following tables. For criticalapplications,as determined
byToro,eitherthe recommended torque or a torquethat
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
(e.g. Nylock nut), hardness of the surface underneath
thefastener’sheador similar conditionwhichaffectsthe
installation.
Fastener Identification
Asnoted inthefollowingtables, torquevaluesshould 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.
Measurethetorquerequiredto tighten the fastener until
thelinesmatchup.
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
Useof anoffsetwrench(e.g.crowfoot wrench)willaffect
torquewrench calibration due to the effective change of
torque wrench length.When using atorque 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”.
Themeasuredeffectivelengthofthe torquewrenchwith
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
T orque wrenchOffset wrench
The calculated t orque conversion factor for this torque
wrenchwith this offset wrench would be 18 / 19= 0.947.
Groundsmaster 4100--D Page 2 -- 3 Product Records and Maintenance
Rev. A
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 + 56
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 4100--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 4100--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 + 14N--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 4100--DPage 2 -- 6Product Records and Maintenance
Table of Contents
GENERAL INFORMATION 2.....................
Operator’s Manual 2..........................
Stopping the Engine 2.........................
SPECIFICATIONS 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 14........................
Spring Coupler 16.............................
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
V2403--M--T--E3B SERIES
Chapter 3
Kubota Diesel Engine
Kubota
Diesel Engine
Groundsmaster 4100--D Page 3 -- 1 Kubota Diesel Engine
General Information
ThisChapter gives informationaboutspecificationsand
repair of the diesel engine used in the Groundsmaster
4100--D.
Generalmaintenance procedures are described inyour
Operator’sManual.Informationonenginetroubleshooting,testing, disassembly and reassemblyis identifiedin
the Kubota Workshop Manual, Diesel Engine,
V2403--M--T--E3Bthat is included at the endofthissection.
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,
DieselEngine,V2403--M--T--E3B.Theuseofsomespecialized test equipment is explained. However,the cost
of the test equipment and the specialized nature of
somerepairsmaydictatethattheworkbedoneatanengine 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.
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 5 minutes. Failure to do so may lead to turbocharger trouble.
Groundsmaster 4100--DPage 3 -- 2Kubota Diesel Engine
Specifications
Item Description
Make / Designation Kubota Model V2403--M--T--E3B: 4--Cycle, 4 Cylinder,
Water Cooled, Turbocharged, Diesel Engine
Bore 3.43” (87.0 mm)
Stroke 4.031” (102.4 mm)
Total Displacement cc (cu. in.) 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 Ultra Low
Sulfur Content
Fuel Capacity 19.0 U.S. gallons (72 liters)
Fuel Injection Pump Denso PFR 4M Type Mini Pump
Injection Nozzle Denso OPD Mini Nozzle
Kubota
Diesel Engine
Governor Centrifugal Mechanical
Low Idle (no load) 1450 + 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 10.0 U.S. Quarts (9.5 Liters) with Filter
Oil Pump Trochoid Type
Coolant Capacity 13 U.S. Quarts (12.3 Liters)
Starter 12 VDC, 2.0 kW
Alternator/Regulator 12 VDC
Standard Alternator 40 amp
Optional Alternator 90 amp
Engine Dry Weight 419 U.S. pounds (190 kg)
Groundsmaster 4100--D Page 3 -- 3 Kubota Diesel Engine
Service and Repairs
Air Filter System
RIGHT
7
FRONT
10
11
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)
1
9
12 to 15 in--lb
(1.4 to 1.6 N--m)
12
6
11
13
14
4
15
8
2
5
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)
VACUATOR
DIRECTION
Groundsmaster 4100--DPage 3 -- 4Kubota Diesel Engine
Removal (Fig. 1)
1. Parkmachineon a level surface, lower cutting deck,
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. If service indicator (item 8) and adapter (item 9)
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). Torque indicator 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
1
3
Figure 2
4. Air cleaner cover
5. Vacuator valve
Kubota
Diesel Engine
2
3
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 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
2
1. Air cleaner hose
2. Engine valve cover
3. Air cleaner strap
Figure 3
3. Adapter
1
5
Figure 4
4. Air cleaner slots
5. Muffler bracket
Groundsmaster 4100--D Page 3 -- 5 Kubota Diesel Engine
Exhaust System
RIGHT
FRONT
16 to 22 ft--lb
(21to29N--m)
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 4100--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. Parkmachine on a level surface, lower cutting deck,
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.
B
E
C
D
A
Kubota
Figure 6
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. Installexhaust system components to theengineusing 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 nuts that secure muffler to muffler
bracket from 16 to 22 ft--lb (21 to 29 N--m).
C. Torque flange head screws that secure muffler
flange to engine 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 that secure exhaust mount
to engine to 1 3 f t -- l b ( 1 7 . 6 N -- m ) .
3. Tailpipeshouldhave equalclearancebetweenframe
and engine after installation.
4. Lower and secure hood.
Groundsmaster 4100--D Page 3 -- 7 Kubota Diesel Engine
Rev. A
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. Flange nut
8. Cap screw (4 used)
9. Flat washer
10. Cap screw (4 used)
11. Carriage screw (2 used)
12. Washer
13. Battery strap
14. Battery
18
17
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 battery cable
21. Positive battery cable
22. Carriage screw (2 used)
23. Gasket
24. Bushing (3 used)
25. Stand pipe
26. Fuel sender
27. Lock washer (5 used)
28. Phillips head screw (5 used)
8
135 to 165 ft--lb
9
10
29. Fuel hose
30. Hose clamp
31. Elbow fitting
32. Fuel cap
33. Locking flange nut
34. Speed nut
35. Tank cover (2 used)
36. Phillips head screw
37. Vent tube
38. Insulated clip (3 used)
39. Washer head screw (3 used)
40. Hose clamp
41. ROPS assembly
(183 to 223 N--m)
Groundsmaster 4100--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, leaks 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.
1. Install fuel tank using Figure 7 as a guide.
A. Torque two (2) 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 fuel sender.
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.
5. Positionbatteryinmachine.Connectpositivebattery
cable first and then negative battery cable. Install battery strap and cover.
Kubota
Diesel Engine
Fuel Tank Removal (Fig. 7)
1. Parkmachineon a level surface, lower cutting deck,
stop engine, engage parking brake and remove key
from the ignition switch.
2. Raise and support seat and hood.
3. Remove battery cover and strap. Disconnect negative battery cable first and then positive battery cable.
Remove battery from machine.
4. Usea fuel transfer pump toremove fuelfrom the fuel
tank and into a suitable container.
5. Disconnect electrical wiring from the fuel sender on
the fuel tank.
6. Disconnectfuelhosefromthestandpipe andventing
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.
8. Remove fuel tank using Figure 7 as a guide.
6. Lower seat and hood.
7. Fill fuel tank.
Groundsmaster 4100--D Page 3 -- 9 Kubota Diesel Engine
Radiator
61
32
13
RIGHT
FRONT
14
35
34
38
48
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 8
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 4100--DPage 3 -- 10Kubota Diesel Engine
Removal (Fig. 8)
Installation (Fig. 8)
1. Parkmachineon a level surface, lower cutting deck,
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. Disconnectupper and lower radiator hoses fromthe
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. Positionlower radiatorshroudandfan motor bracket
assembly to the radiator.
4. Secure fan motor bracket to radiator with six (6)
flange head screws and flange nuts.
5. Position upper radiator shroud to lower radiator
shroud to radiator. Secure shrouds with removed fasteners.
6. 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.
7. Connectreservoir hose to the vent tube near the radiator cap.
8. Connectupperandlowerradiatorhosesto theradiator.
9. Reinstall air cleaner hose (item 61).
Kubota
Diesel Engine
7. Detach upper radiator shroud from the radiator and
lower radiator shroud. Remove upper shroud from machine.
8. Removefasteners that secure lower radiatorshroud
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.Removecapscrewsand flangenutssecuringthe radiator to the support frame. Carefully pull radiator from
the machine.
12.Plugallradiatororhoseopeningstopreventcontamination.
10.Make sure radiator drain is closed. Fill radiator with
coolant.
11.Close and secure hood.
Groundsmaster 4100--D Page 3 -- 11 Kubota Diesel Engine
Engine
21
20
23
22
13
RIGHT
FRONT
19
18
24
25
17
26
16
13
15
14
13
27
12
1
2
3
4
5
6
11
7
8
9
10
9
Loctite #242
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)
29 to 33 ft--lb
28 to 32 ft--lb
(38to43N--m)
(40to44N--m)
Figure 9
10. Rebound washer (4 used)
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
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
Groundsmaster 4100--DPage 3 -- 12Kubota Diesel Engine
Engine Removal (Fig. 9)
1. Parkmachineon a level surface, lower cutting deck,
stop engine, apply parking brake and remove key from
the ignition switch.
2. Remove battery cover and strap. Disconnect negative battery cable first and then positive battery cable.
Remove battery from machine.
2
3. 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.
4. Drain coolant from the radiator into a suitable container (see Radiator Removal in this section). Disconnect upper and lower hoses from the radiator.
CAUTION
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the exhaust system
to cool before working on or near the muffler.
5. Remove exhaust system from engine (see Exhaust
System Removal in this section).
1
Figure 10
1. Dual temperature switch
2. Temperature sender
1
Figure 11
1. Glow plug wire
2. Glow plug lead
3
3. Alternator
3
3. Cylinder #4 glow plug
2
Kubota
Diesel Engine
6. Removeaircleaner system from engine (see Air Filter System Removal in this section).
1
2
7. Note location of cable ties used to secure wire harness to the machine. Disconnect wires and/or electrical
3
connections from the following electrical components:
A. The dual temperature switch, temperature sender and alternator (Fig 10).
B. The glow plug lead (Fig. 11).
C. The engine run solenoid (Fig. 12).
D. Battery,frameandwireharness groundattheen-
1. Engine run solenoid
2. Alternator belt
Figure 12
3. Throttle cable
gine block.
E. The electric starter and low oil pressure switch
(on RH side of engine).
8. Disconnect fuel supply hose from injection pump
(Fig. 13).
Groundsmaster 4100--D Page 3 -- 13 Kubota Diesel Engine
9. Disconnect throttle cable from the speed control lever by removing the flat washer and lock nut (Fig. 14).
Loosenjam nut andseparate cable from cable support.
Position cable away from engine.
10.Remove fasteners that secure the upper radiator
shroud to the lower shroud and radiator (see Radiator
Removal in this section). Position coolant reservoir and
bracket away from the radiator. Remove upper radiator
shroud from machine.
1
3
11.Remove fan hub and fan from hydraulic fan motor
(Fig. 15).
A. Removehex nut(item9)and washer (item8)that
secure fan hub and fan assembly to fan motor.
NOTE: The fan motor shaft is tapered.
B. Usesuitablepullertoremove fanhub(with fanat-
tached) from fan motor shaft taking care to not damage fan. Remove fan hub and fan from machine.
IMPORTANT: The hydraulic pump assembly can remain in machine during engine removal. Toprevent
pump from shifting or falling, make sure to support
pump assembly before mounting fasteners are removed.
12.Support hydraulic pump assembly. Remove fasteners that secure pump assembly to engine (see Pump
Assembly Removal in the Service and Repairs section
of Chapter 4 -- Hydraulic System).
13.Make sure all cable ties securingthewiringharness,
fuellines or hydraulic hoses to the engine are removed.
14.Connect hoist or lift to the lift tabs on engine.
15.Remove flange nuts, rebound washers and cap
screws securing the engine mounts to the engine supports.
1. Fuel pump
2. Fuel supply hose
1. Lock nut
2. Flat washer
3. Throttle lever
4. Lock nut
5. Flange head screw
6. Cap screw
Figure 13
3. Throttle cable
1
12
Figure 14
7. Flange head screw
8. Spring washer (2 used)
9. Ball joint
10. Cap screw (2 used)
11. Throttle cable
12. Cable support
2
3
2
4
5
8
6
7
9
10
11
CAUTION
One person should operate lift or hoist while
another person guides the engine out of the machine.
IMPORTANT: Make sure not to damage the engine,
fuel and hydraulic lines, electrical harness or other
components while removing the engine.
16.Slowly remove engine assembly from the machine.
17.Ifnecessary,removeengine mountsfromthe engine
using Figure 9 as a guide.
Engine Installation (Fig. 9)
1. Ifremoved,installengine mountstothe engineusing
Figure 9 as a guide.
2. Connect hoist or lift to the engine lift tabs.
CAUTION
One person should operate lift or hoist while
another person guides the engine into the machine.
IMPORTANT: Make sure not to damage the engine,
fuel and hydraulic lines, electrical harness or other
parts while installing the engine.
Groundsmaster 4100--DPage 3 -- 14Kubota Diesel Engine
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