Toro 4300-D User Manual
Part No. 10178SL
Service Manual
Groundsmaster
Preface
The purposeof thispublication isto providethe service
technician with information for troubleshooting, testing
and repair of major systems and components on the
Groundsmaster 4300--D.
REFER TO THEOPERATOR’S MANUALFOROPERATING, MAINTENANCE AND ADJUSTMENT
INSTRUCTIONS.Spaceis provided in Chapter2 of this
book to insertthe Operator’s Manual and Parts Catalog
for your machine. Additional copies of the Operator’s
Manual and Parts Catalog are available on the internet
at www.Toro.com.
TheToroCompany reservestherightto changeproduct
specifications or this publication without notice.
R
4300--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 willgive 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 -- 2010
This page is intentionally blank.
Groundsmaster 4300--D
Table Of Contents
Chapter 1 -- Safety
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 -- 1........................
Specifications 3 -- 2..............................
Adjustments 3 -- 3...............................
Service and Repairs 3 -- 4........................
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
05--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 -- 22.............................
Troubleshooting 4 -- 26...........................
Testing 4 - - 32...................................
Service and Repairs 4 -- 60.......................
SAUER--DANFOSS LPV CLOSED CIRCUIT AXIAL
PISTON PUMPS REPAIR MANUAL
SAUER--DANFOSS LPV CLOSED CIRCUIT AXIAL
PISTON PUMPS SERVICE INSTRUCTIONS
PARKER TORQMOTOR
(TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)
SAUER--DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
TM
SERVICE PROCEDURE
Chapter 5 -- Electrical System
General Information 5 -- 3........................
Special Tools 5 -- 4..............................
Troubleshooting 5 -- 6............................
Electrical System Quick Checks 5 -- 17.............
Adjustments 5 -- 19..............................
Component Testing 5 -- 22........................
Service and Repairs 5 -- 44.......................
Chapter 6 -- Chassis
Specifications 6 -- 2..............................
General Information 6 -- 2........................
Special Tools 6 -- 2..............................
Service and Repairs 6 -- 4........................
Chapter 7 -- Cutting Decks
Specifications 7 -- 2..............................
General Information 7 -- 3........................
Troubleshooting 7 -- 4............................
Special Tools 7 -- 5..............................
Adjustments 7 -- 6...............................
Service and Repairs 7 -- 8........................
Chapter 8 -- Foldout Drawings
Hydraulic Schematic 8 -- 3........................
Electrical Schematic 8 -- 4........................
Wire Harness Drawings 8 -- 6.....................
SafetyProduct Records
and Maintenance
Engine
Kubota Diesel
System
Hydraulic
System
Chassis
Groundsmaster 4300--D
Decks
Cutting Electrical
Foldout
Drawings
This page is intentionally blank.
Groundsmaster 4300--D
Table of Contents
SAFETY INSTRUCTIONS 2......................
Before Operating 2............................
While Operating 3.............................
Maintenance and Service 4....................
JACKING INSTRUCTIONS 5.....................
SAFETY AND INSTRUCTION DECALS 6..........
Chapter 1
Safety
Safety
Groundmaster 4300--D Page 1 -- 1 Safety
Safety Instructions
Your Groundsmastermeetsor exceedssafetystandard
specifications when weights are installed according to
information in the Operator’s Manual. Although hazard
control andaccident preventionare partiallydependent
uponthe design andconfigurationofthe machine, these
factors are also dependent upon the awareness, concern and propertraining ofthe personnelinvolved inthe
operation, transport, maintenance and storage of the
machine. Improper use or maintenanceof the machine
can result in injury or death. To reduce the potential for
injury or death,comply with the following safety instructions.
Before Operating
WARNING
To reduce the potentialfor injuryordeath,comply with the following safety instructions.
1. Review and understand the contents of the Operator’ sManual and OperatorTrainingDVD beforestarting
and operating the machine. Become familiar with the
controls andknow how to stopthe machineand engine
quickly. A replacement Operator’s Manual is available
on the Internet at www.Toro.com.
2. Keep all shields, safetydevicesand decals inplace.
If a shield, safety device or decal is defective, illegible
or damaged, repair or replace it before operating the
machine.
3. Tighten any loose nuts, bolts or screws to ensure
machine is in safe operating condition.
4. Assure interlock switches are adjusted correctly so
engine cannot be started unless traction pedal is in
NEUTRAL and PTO switch is OFF (disengaged).
5. Since dieselfuel is highly flammable, handle itcarefully:
A. Store fuel in containers specifically designed for
this purpose.
B. Do not remove machine fuel tank cap while engine is hot or running.
C. Do not smoke while handling fuel.
D. Fill fueltank outdoorsandonlytowithinaninchof
the topof the tank, not thefiller neck.Do not overfill.
E. After refueling machine, install fuel tank andfuel
container caps.
F. Iffuel is spilled,do notattempttostart theengine
but move the machine away from the area of spillage. Avoid creating any source of ignition until fuel
vapors have dissipated. Wipe up any spilled fuel.
Groundsmaster 4300--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 thetraction pedalis in NEUTRALand
the PTO switch is OFF (disengaged).
C. Afterengineisstarted, releaseparking brakeand
keepfoot off tractionpedal. Machinemust not move.
If movement is evident, the traction pedal linkage is
adjusted incorrectly; therefore, shut engine off and
adjust traction pedal linkage until machine does not
move when traction pedal is released (see Operator’ s Manual).
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, radiator or exhaust system
whileengineisrunningor soonafter it is stopped. These
areas could be hot enough to cause burns.
5. Before getting off the seat:
A. Ensure that traction pedal is in NEUTRAL.
B. Lower and disengage cutting decks and wait for
all movement to stop.
C. Apply parking brake.
D. Stop engine and removekey from ignitionswitch.
6. Anytime the machineis parked (short or long term),
the cuttingdecksshould belowered totheground. This
relieves pressurefrom thehydraulic liftcircuit and eliminates the risk of the cutting decks unexpectedly lowering to the ground.
7. Do not parkon slopesunlesswheels arechockedor
blocked.
Safety
Groundmaster 4300--D Page 1 -- 3 Safety
Maintenance and Service
1. Before servicing or making adjustments, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch.
2. Make suremachineis in safeoperating conditionby
keeping all nuts, bolts and screws tight.
3. Never store the machine or fuel container inside
wherethereisanopenflame, such asneara waterheater or furnace.
4. Makesure all hydraulic line connectorsare tight,and
all hydraulic hoses and lines are in good condition before applying pressure to the hydraulic system.
5. Keepbody andhandsawayfrompinhole leaks inhydrauliclines that ejecthigh pressurehydraulic 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 removedwithin a fewhours bya doctor familiar with this form of injury or gangrene may result.
6. Before disconnecting or performing any work on the
hydraulicsystem, allpressurein the system must berelieved by using all of the hydraulic controls (seeRelieving Hydraulic Pressure in the General Information
section of Chapter 4 -- Hydraulic System).
7. Use care when checking or servicing the cutting
decks. Wear gloves and use caution when servicing
them.
8. To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt. Clean
protective screen on machine frequently.
12.Disconnect battery before servicing the machine.
Disconnect negative battery cable first and positive
cablelast. If batteryvoltage is required for troubleshooting or test procedures, temporarily connect the battery.
Reconnect positive battery cable first and negative
cable last.
13.Battery acid is poisonous and can cause burns.
Avoid contactwithskin, eyesand 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.When changing attachments, tires or performing
other service, use correct supports, hoists and jacks.
Make sure machine is parked on asolid level floor such
asaconcrete floor. Prior toraising the machine,remove
any attachments that may interfere with the safe and
proper raising of the machine. Always chock or block
wheels. Use jackstandsor appropriate load holdingdevices to support the raised machine. If the machine is
not properly supported, the machine may move or fall,
whichmay result in personal injury (see JackingInstructions in this section).
16.Ifmajor repairs areever needed or assistance is desired, contact an Authorized Toro Distributor.
17.When welding on machine, disconnect all battery
cables toprevent damageto machine electronicequipment. Disconnect negative battery cable first and positive cable last. Also, disconnect the wire harness
connector from the machine controller and disconnect
the terminalconnectorfrom thealternator.Attach welder ground cableno morethantwo (2)feet (0.61meters)
from the welding location.
9. If engine must be runningto performmaintenanceor
to make an adjustment, keep hands, feet, clothing and
other partsof thebody away fromthe cuttingdecksand
other moving parts. Keep bystanders away.
10.Do not overspeed the engine by changing governor
setting. T oassuresafetyandaccuracy,check maximum
engine speed with a tachometer.
1 1.Shut engine off before checking or adding oil to the
crankcase.
18.At the time of manufacture, your Groundsmaster
conformed to thesafety standardsforriding mowers.To
assure optimum performanceand continuedsafetycertification ofthemachine,usegenuine Tororeplacement
parts and accessories. Replacement parts and accessories madeby other manufacturers may result innonconformance with the safety standards, and the
warranty may be voided.
Groundsmaster 4300--DPage 1 -- 4Safety
Jacking Instructions
CAUTION
When changing attachments, tiresor performing otherservice, use correctsupports,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 other appropriate load holding devices to support the
raised machine. If the machine is not properly
supported, the machine may move or fall,
which may result in personal injury.
Front End Jacking
1. Applyparking brake and chockboth reartirestoprevent the machine from moving.
2. Position jack securely under the rectangular padon
the frame axle tube, just to the inside of the front wheel
(Fig. 1).
3. Jack front of machine off the ground.
4. Position jackstands under the frame as close to the
wheel as possible to support the machine.
Safety
2
1
Figure 1
1. Front wheel 2. Front jacking point
2
1
3
Rear End Jacking
1. Applyparkingbrakeandchockbothfront tires toprevent the machine from moving.
2. Place jacksecurelyat thecenter of the rear axleunder the axle pivot bracket. Jack rear of machine off the
ground.
3. Position jack stands under the frame to support the
machine.
1. Rear wheel
2. Rear axle pivot bracket
Figure 2
3. Jack stand location
Groundmaster 4300--D Page 1 -- 5 Safety
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
the traction unit and cutting units of your Groundsmaster. If any decal becomes illegible or damaged, installa
new decal. Part numbers for decals are listed in your
Part Catalog. Order replacement decals from your Authorized Toro Distributor.
Groundsmaster 4300--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 Series) 5..............
Other Torque Specifications 6..................
Conversion Factors 6..........................
Chapter 2
Product Records
and Maintenance
Product Records
Insert Operator’s Manual and Parts Catalog for your
Groundsmaster at the end of this chapter. Additionally,
if any optional equipment or accessories have been
installedto your machine, insertthe Installation Instructions, Operator’s Manuals andParts Catalogsfor those
options at the end of this chapter.
Maintenance
Maintenanceprocedures andrecommendedservice intervals for your Groundsmaster areidentified in theOperator’s Manual. Refer to that publication when
performing regular equipment maintenance.
Groundsmaster 4300--D Page 2 -- 1 Product Records and Maintenance
Equivalents and Conversions
0.09375
Groundsmaster 4300--DPage 2 -- 2Product Records and Maintenance
Torque Specifications
Recommended fastener torque values are listed in the
followingtables.Forcriticalapplications,as determined
byToro,eitherthe recommended torque oratorque that
is unique to theapplication isclearly identifiedand specified in this Service Manual.
These Torque Specifications for the installation and
tightening of fasteners shallapply to allfasteners which
donot have a specific requirement identified inthis 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 ofa prevailing torquefeature
(e.g. Nylock nut), hardness of the surface underneath
thefastener’sheadorsimilarcondition whichaffectsthe
installation.
Fastener Identification
Asnoted inthe followingtables,torquevaluesshouldbe
reduced by 25% for lubricated fasteners to achieve
the similarstress 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 onthe 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 fasteneruntil
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
torquewrenchcalibration due to the effective change of
torquewrench length. When using atorquewrenchwith
an offset wrench, multiplythe 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: Themeasured effectivelength 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
wrenchwiththisoffsetwrench would be 18 / 19 = 0.947.
Groundsmaster 4300--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 inthe tableabove
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 and8 fasteners arebased on 75%of the minimumproofload specified in SAE J429. The toleranceis
approximately +
10% of the nominal torquevalue. Thin
height nuts include jam nuts.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specifictorque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Groundsmaster 4300--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 inthe tableabove
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 specifictorque 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 4300--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. Alltorque values arebasedon non--lubricated fasteners.
Groundsmaster 4300--DPage 2 -- 6Product Records and Maintenance
Table of Contents
Chapter 3
Kubota Diesel Engine
GENERAL INFORMATION 1.....................
Operator’s Manual 1..........................
Stopping the Engine 1.........................
SPECIFICATIONS 2............................
ADJUSTMENTS 3..............................
Adjust Throttle Control 3.......................
General Information
This Chapter gives information about specifications,
troubleshooting, testing andrepair of the Kubota diesel
engine used in the Groundsmaster 4300--D.
Most repairs and adjustments require tools which are
commonly available in many service shops. The useof
some specialized test equipment isexplained in theengine workshopmanual included at the endof thischapter. However, the cost of the test equipment and the
specialized natureof some repairs may dictate thatthe
work be done at an engine repair facility.
SERVICE AND REPAIRS 4......................
Fuel System 4................................
Air Cleaner 6.................................
Exhaust System 8............................
Radiator 10..................................
Engine 12....................................
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
05--E3B SERIES
Service and repair parts for Kubota diesel engines are
suppliedthroughyour local T oroDistributor.If a parts list
is not available, be sure to provide your distributor with
the Toro model and serial number.
Engine
Kubota Diesel
Operator’s Manual
The Operator’s Manual provides information regarding
the operation, general maintenance and maintenance
intervals for the Kubota diesel engine that powers your
Groundsmaster machine. Refer to that publication for
additional information when servicing the machine.
Stopping the Engine
IMPORTANT: The engine used on the Ground smaster 4300--D isturbo--charged. Beforestopping
theengine aftermowing or full load operation,cool
the turbo-charger by allowing the engine to idle at
low speedfor five(5) minutes. Failure to do so may
lead to turbo-charger trouble.
Groundsmaster 4300--D Page 3 -- 1 Kubota Diesel Engine
Specifications
Item Description
Make / Designation Kubota V1505--T--E3B, 4--stroke,
Number of Cylinders 4
Bore x Stroke 3.07 in x 3.09 in (78 mm x 78.4 mm)
Total Displacement 91.4 in3(1498 cc)
CompressionRatio 23:1
Firing Order 1 (fan end) -- 3 -- 4 (flywheel end) -- 2
Fuel No. 2--D Diesel Fuel (ASTM D975)
Fuel Injection Pump Bosch MD Type Mini
Fuel Injector Nozzle MiniNozzle (DNOPD)
Fuel Tank Capacity 14 U.S. gallons (53liters)
Governor Centrifugal Mechanical
Low Idle Speed(no load) 1250 to 1350 RPM
High Idle Speed (no load) 3050 to 3250 RPM
Liquid Cooled, OHV, Turbocharged Diesel
Engine Oil API Classification CI--4 or Higher
Oil Pump Gear Driven Trochoid Type
Crankcase Oil Capacity 5.5 U.S. quarts (5.2 liters) with Filter
Cooling System Capacity (including reserve tank) 10 U.S. quarts (9.5 liters)
Starter 12 VDC 1.2 KW
Alternator/Regulator 12 VDC 40 Amp
Engine Dry Weight (approximate) 251 lbs (114 kg)
(see Operator’s Manual for viscosity recommendations)
Groundsmaster 4300--DPage 3 -- 2Kubota Diesel Engine
Adjustments
Adjust Throttle Control
Proper throttle operation is dependent upon proper adjustment of throttle control.
NOTE: The throttle cable swivel should be positioned
in the lowest hole in the speed control lever .
2
1. Move throttle control lever on control console to
FAST position.
2. Check position of the engine speed control lever on
fuel injection pump. The speed control lever should be
contacting the high speed screw whenthe throttlecontrol lever is in the FAST position.
3. If necessary,throttle controlcanbeadjustedbylooseningcable clampscrew andrepositioning control cable
until speed control lever contacts high speed screw
when the throttle control lever is in the FAST position.
Tighten cable clamp screw after adjustment has been
completed.
5
1
1. Throttle cable
2. High speed screw
3. Speed control lever
Figure 1
3
4
4. Swivel
5. Cable clamp
Engine
Kubota Diesel
Groundsmaster 4300--D Page 3 -- 3 Kubota Diesel Engine
Service and Repairs
Fuel System
16
8
7
12
15
1
6
11
9
10
2
13
14
4
17
18
19
RIGHT
FRONT
1. Fuel cap
2. Bushing
3. Washer head screw (2 used)
4. Flange nut (3 used)
5. Clamp (2 used)
6. Returnfitting
7. Suction fitting
8. Hose clamp
9. Hose clamp
10. Fuel tank
11. Grommet
12. Fuel gauge
13. Hose clamp
3
5
4
Figure 2
14. Draincock
15. Fuel supply hose
16. Fuel return hose
17. Bumper
18. Flat washer
19. Cap screw
Groundsmaster 4300--DPage 3 -- 4Kubota Diesel Engine
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
tankwhile engineis running, whenengineis hot
or when machine is in an enclosed area. Always
fill fuel tankoutsideand wipe up any spilled dieselfuelbefore startingtheengine. Store fuel in a
clean, safety--approved container and keepcontainer cap inplace.Use dieselfuel for theengine
only; not for any other purpose.
3. Opendraincockonbottomoffueltankandallow tank
to fully drain. Close draincock.
NOTE: Before removing fuel hoses from tank fittings,
label hoses for assembly purposes.
4. Loosenhose clampsanddisconnect fuel hoses from
suction (item 7) andreturn (item 6) fittings onthe top of
the fuel tank.
5. Remove fuel tank using Figure 2 as a guide.
Fuel Tank Installation (Fig. 2)
1. Install fuel tank to frame using Figure 2 as a guide.
Check Fuel Hoses and Connections
Check fuel hoses and connections periodically as recommended in theOperator’s Manual. Checkfuelhoses
for deterioration, damage, leakage or loose connections. Replace fuel hoses, clamps and connections as
necessary.
Drain and Clean Fuel Tank
Drain and clean the fuel tank periodically as recommendedinthe Operator’sManual. Also,drainandclean
the fuel tank if the fuel system becomes contaminated
or if the machineis tobestored foran extendedperiod.
To clean fuel tank, flush tank out with clean diesel fuel.
Make sure tank is free of all contaminates and debris.
Fuel Tank Removal (Fig. 2)
1. Park machine on a level surface, lower cutting
decks, stop engine, apply parking brake and remove
key from the ignition switch.
2. Placedrainpanunder fueltank. Make sure that drain
pan is large enough to hold fuel tank contents (see
Specifications in this chapter).
2. Using labels placed during fuel tank removal, correctly connect fuel hoses to suction (item 7) and return
(item 6) fittings on the top of the fuel tank. Secure fuel
hoses with hose clamps.
3. Make sure thatfuel tank draincock is closed.Fillfuel
tank.
1
3
2
Figure 3
1. Fuel supply hose
2. Fuel return hose
3. Fuel gauge
Engine
Kubota Diesel
Groundsmaster 4300--D Page 3 -- 5 Kubota Diesel Engine
Air Cleaner
19
17
14
18
14
8
11
11
7
1
Thread
Sealant
11
6
4
3
16
5
2
12 to 15 in--lb
(1.4 to 1.6 N--m)
RIGHT
FRONT
1. Air cleaner assembly
2. Indicator
3. Adapter
4. Spring
5. Hex nut
6. Bolt
7. Hose
12
13
10
15
12
Figure 4
8. Hose
9. Mount bracket
10. Air cleaner stand
11. Hose clamp (3 used)
12. Flange nut (8used)
13. Cap screw (2 used)
14. Hose clamp (2 used)
12
12
VACUATOR
DIRECTION
9
20
15. Flange head screw (4 used)
16. Air cleaner mountingband
17. Spacer
18. Hose
19. Hose clamp
20. Flange head screw (2 used)
Groundsmaster 4300--DPage 3 -- 6Kubota Diesel Engine
Removal (Fig. 4)
1. Park machine on a level surface, lower cutting
decks, stop engine, engage parking brake and remove
key from the ignition switch. Raise and support hood.
2. Remove air cleaner components as needed using
Figures 4 as a guide.
3. See Operator’s Manual for air cleaner service and
maintenance procedures.
Installation (Fig. 4)
IMPORTANT: Any leaks in the air filter system will
allowdirt into engineand will causeseriousengine
damage. Make sure that all air cleanercomponents
areingood conditionand areproperlysecured during assembly.
1. Assemble air cleaner system using Figure 4 as a
guide.
A. If service indicator (item 2) and adapter (item 3)
wereremovedfromaircleanerhousing,applythread
sealant to adapter threads before installing adapter
and indicator to housing. Install adapter so that
groovesinadapter hex andadapterfilter elementare
installed towardservice indicator (Fig.5).Torque indicator from 12 to 15 in--lb (1.4 to 1.6 N--m).
1
4
1. Air cleaner assembly
2. Service indicator
3
Figure 5
3. Adapter
4. Vacuator valve
2
Engine
Kubota Diesel
B. Makesurethatvacuator valve ispointeddownafter assembly.
Groundsmaster 4300--D Page 3 -- 7 Kubota Diesel Engine
Exhaust System
3
RIGHT
13
1
FRONT
6
10
11
7
12
16
4
2
5
5
8
9
14
17
1. Gasket
2. Lock washer (2 used)
3. Flange nut (4 used)
4. Cap screw (2 used)
5. Carriage screw (4 used)
6. Flange nut (4 used)
6
15
7. Muffler support bracket
8. Flange head screw (2 used)
9. Tail pipe bracket
10. Hex nut (2 used)
11. Upper clamp
12. Flange nut (4used)
Figure 6
13. Exhaust header
14. Flange head screw (2 used)
15. Muffler
16. Tail pipe bracket
17. Lower clamp
Groundsmaster 4300--DPage 3 -- 8Kubota Diesel Engine
Removal (Fig. 6)
1. Park machine on a level surface, lower cutting
decks, stop engine, engage parking brake and remove
key from the ignition switch. Raise and support hood.
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 exhaust system.
2. Remove exhaust system using Figure 6 as a guide.
Installation (Fig. 6)
NOTE: Make sure mufflerflange and exhaustmanifold
sealing surfaces arefree of debris or damage that may
prevent a tight seal.
1. Place new muffler gasket on the exhaust manifold.
2. If muffler support bracket (item 7) was removed,secure it to engine with removed fasteners.
3
2
1 (FIRST)
4 (LAST)
Figure 7
Engine
Kubota Diesel
IMPORTANT: Fingertighten all exhaust systemfastenersbeforetightening so that there is no preload
on the exhaust system due to exhaust system assembly.
3. Installexhaust system components to the engineusing Figure 6as aguide. Finger tighten allfasteners until
all exhaust system components have been installed.
4. Tightenexhaust systemfastenersinthefollowingorder:
A. Lift muffler as much as holes in muffler support
bracket (item 7) will allow. Tighten flange nuts (item
6) to secure muffler to support bracket.
B. Tighten flange nuts (item 3) to secure exhaust
header (item 13)toengine flangeusing ordershown
in Figure 7.
C. Tighten hex nuts (item10) tosecureupper clamp
(item 11).
D. If tail pipe bracket(item 9) was removed, tighten
flange head screws (item 14) to secure bracket to
engine.
E. Tighten flange nuts (item 12) to secure lower
clamp (item 17).
F. Tighten fasteners (items 8 and 12) to secure tail
pipe brackets (items 9 and 16).
Groundsmaster 4300--D Page 3 -- 9 Kubota Diesel Engine
Radiator
RIGHT
FRONT
27
9
41
40
45
35
16
16
28
36
19
20
20
12
22
8
5
15
42
44
43
37
18
46
13
5
12
47
5
17
39
7
29
31
4
11
13
10
26
25
10
2
10
3
2
1
34
23
1. Overflow bottle
2. Hose clamp (3 used)
3. Hose
4. Foam seal (2 used)
5. Foam seal (4 used)
6. Mounting bracket (2 used)
7. Oil cooler
8. Pipe plug
9. Hydraulic fitting (2 used)
10. Hose clamp (4 used)
11. Foam seal (2 used)
12. Flange nut (4used)
13. Flange nut (17used)
14. Oil cooler mount plate (2used)
15. Flange head screw (6 used)
16. Hose clamp (4 used)
33
6
2
21
5
38
13
24
Figure 8
17. Flange head screw (8 used)
18. Clamp (2 used)
19. Cap screw (2 used)
20. Washer (4 used)
21. Radiator
22. Radiator frame
23. Reservoir bracket
24. Reservoir bracket
25. Upper radiator hose
26. Lower radiator hose
27. Fan shroud
28. Hydraulic hose (2 used)
29. Rivet (2 used)
30. Flange head screw (10 used)
31. Draw latch
32. Washer head screw (6 used)
17
14
30
15
30
32
13
33. Flange head screw
34. Lock nut
35. O--ring
36. Screen
37. Intake screen
38. Hose
39. Oil cooler bracket
40. O--ring
41. Hydraulic tube
42. Foam seal
43. Spacer (5 used)
44. Flange head screw (5 used)
45. Hydraulic fitting (2 used)
46. Pin
47. Radiator cap
Groundsmaster 4300--DPage 3 -- 10Kubota Diesel Engine
Removal (Fig. 8)
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 the 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.
10.Carefully pull radiator assembly from the machine.
Plug radiatorand hoseopenings toprevent contamination.
1 1.Inspect all foam seals placed between radiator , fan
shroud and radiator frame. Replace damaged foam
seals.
Installation (Fig. 8)
1. Remove plugs placedin radiatorand hose openings
during the removal procedure.
2. Carefully position radiator assembly to the radiator
support. Position fan shroud to the radiator.
Ethylene--glycol antifreeze is poisonous. Disposeof coolant properly, or storeitin aproperly
labeled container away from children and pets.
3. Drain coolant from radiator.
A. Slowly remove radiator cap from the radiator .
B. Place drain pan below the radiator draincock lo-
cated on the bottom of the radiator. Make sure that
drainpanislargeenough toholdcooling systemcontents (10 U.S. quarts (9.5 liters)).
C. Loosen radiator draincock (threaded in) and allow coolant to drain from radiator.
4. Remove screen from machine.
5. Disconnect radiator hoses (upper and lower) from
the radiator.
6. Loosen hose clampand removeoverflowhose from
radiator fill opening.
7. Remove two (2)flangehead screwsand flangenuts
that secure coolant reservoir and brackets to fan
shroud. Carefully position reservoir and brackets away
from the fan shroud.
8. Remove five (5)flange head screwsand flange nuts
that secure air intake screen (item 37) to machine. Remove screen and foam seal (item 42). Locate and retrieve five (5) spacers (item 43).
3. Securefanshroudandradiatortoradiatorframe with
removed flange head screws and flange nuts. Make
sure that atleast 0.250”(6.4mm)clearanceexistsat all
points between shroud opening and fan.
4. Position coolant reservoir and brackets to the fan
shroud. Secure reservoir to fan shroud and radiator
frame with two(2) flange head screws and flange nuts.
5. Place spacers (item43) into holes infoam seal(item
42). Position foam seal and air intake screen (item 37)
to radiator frame. Secure intakescreen tomachine with
five (5) flange head screws and flange nuts.
6. Connect upper and lower radiator hoses to radiator
and secure with clamps.
7. Connect overflow hose to radiator fill opening and
secure with hose clamp.
8. Makesureradiator draincockisclosed (threaded out
fully).
9. To allow air to escape during radiator filling, remove
pipe plug (item 8) from top of radiator. Fill radiator with
coolant. Make suretoinstallplugonceallairis bled from
radiator.
10.After radiator has been properly filled with coolant,
install radiator cap.
1 1.Lower and secure hood.
Engine
Kubota Diesel
9. Removeflange head screws and flange nuts thatsecure fanshroud andradiator to radiator frame. Position
fan shroud away from the radiator.
Groundsmaster 4300--D Page 3 -- 11 Kubota Diesel Engine
Engine
30
1
15
3
11
16
26
18
19
20
5
10
17
4
29
9
RIGHT
FRONT
13
23
9
32
34 to 42 ft--lb
(47to56N--m)
25
22
21
14
31
7
27
5
24
5
4
22
12
23
2
9
6
9
8
9
6
8
28
1. Engine assembly
2. Cap screw (12 used)
3. Temperature sender
4. Engine mount (4 used)
5. Flange head screw (13 used)
6. Snubbing washer (4 used)
7. Cap screw (4 used)
8. Flange nut (4 used)
9. Flange nut (14 used)
10. Fan clutch
11. Stud (4 used)
Figure 9
12. Lock washer
13. Lock washer
14. Pulley
15. V--belt
16. Lock washer (4 used)
17. Cooling fan
18. Flat washer
19. Spring washer
20. Hex nut
21. Cap screw
22. Spacer (4 used)
23. Negative battery cable
24. Air cleaner stand
25. Lock washer (12 used)
26. Fusible link harness
27. Engine mount (4used)
28. Bracket
29. Bracket
30. Hex nut
31. Flange head screw (4 used)
32. Wire harness ground
Groundsmaster 4300--DPage 3 -- 12Kubota Diesel Engine
Removal (Fig. 9)
1. Park machine on a level surface, lower cutting
decks, stop engine and remove key from the ignition
switch. Chockwheelstokeepthemachinefrommoving.
2. Open and support hood.
3. Disconnect negative (--) cable and then positive (+)
cable from the battery.
CAUTION
2
1
3
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. Disposeof coolant properly, or storeitin aproperly
labeled container away from children and pets.
4. Drain coolant from radiator (see Radiator Removal
in this section).
5. Remove air cleaner from machine (see Air Cleaner
Removal in this section).
6. Remove exhaust system from machine (see Exhaust System Removal in this section).
7. Remove throttle cable from injector pump (Fig. 10):
A. Remove cap screw that secures throttle cable
end to swivel in speed control lever.
B. Loosen throttle cable clamp and remove cable
from clamp. Slide throttle cable end from swivel.
C. Position throttle cable away from the engine.
1. Throttle cable end
2. Swivel
1. Fuel return hose
2. Fuel supply hose
Figure 10
1
Figure 11
3. Cable clamp
Engine
Kubota Diesel
2
3
3. Fuel/water filter
8. Disconnect hoses from engine:
A. Loosen clamps and remove upper and lower radiator hoses from the engine.
2
B. At injectorpump, loosenhose clamp anddisconnect supply fuel hose from the injector pump fitting
(Fig. 11).
C. Loosen hose clamp and disconnect fuel return
hose from front injector body (Fig. 11).
1
D. Plug disconnectedhoses andengineopeningsto
preventleakageand contamination.Positiondisconnected hoses away from engine.
1. Negative battery cable 2. Wire harness ground
Figure 12
Groundsmaster 4300--D Page 3 -- 13 Kubota Diesel Engine
9. Disconnect hydraulic transmission drive shaft from
engine (see Hydraulic Transmission Drive Shaft Removal in the Service and Repairs section of Chapter 4
-- Hydraulic System). Support driveshaft away fromengine.
Installation (Fig. 9)
1. Locate machine on alevel surface with cuttingdecks
lowered and key removed from the ignition switch.
Chock wheels to keep the machine from moving.
10.Disconnectwireharness connectorsfrom thefollowing engine components:
NOTE: Before disconnectingwire harnessconnectors,
label all electrical leads for assembly purposes.
A. Alternator connector and stud.
B. Oilpressure switchlocatednear theengine oil fil-
ter.
C. Connector, fusible link connector and positive
battery cable from the starter motor.
D. High temperature shut down switch andtemper-
ature sender located on the water pump housing.
E. Fuel stop solenoid on injector pump.
F. Negative battery cable and wire harness ground
from injector pump (Fig. 12).
G. Glow plug strip.
1 1.Remove engine from machine:
2. Make sure that all parts removed from the engine
duringmaintenance or rebuilding are installedtothe engine.
3. If engine brackets were removed from the engine,
secure brackets to engine with lock washers and cap
screws. Torque cap screws from 34 to 42 ft--lb (47 to
56 N--m).
4. Install engine to machine.
A. Attach short sectionof chainbetween lift tabs lo-
cated on each end of the cylinder head
B. Connect a hoist or lift at the center of the short
section of chain. Apply enough tension on the short
chain so that the engine can be supported.
CAUTION
One person should operate hoist or lift while a
second person guides the engine into the machine.
A. Attach short sectionof chainbetween lift tabs located on each end of the cylinder head.
B. Connect a hoist or lift at the center of the short
section of chain. Apply enough tension on the short
chain so that the engine will be supported.
C. Remove fasteners that secure the engine (with
brackets) to the engine mounts.
CAUTION
One person should operate hoist or lift while a
secondpersonguides theengine out of themachine.
IMPORTANT: Make sure to not damage the engine, fuel hoses, hydraulic lines, electrical harness, radiator, battery or other parts while
removing the engine.
D. Raise engine and remove toward front of machine.
IMPORTANT: Make sure to not damage the engine, fuel hoses, hydraulic lines, electrical harness, radiator, battery or other parts while
installing the engine.
C. Lower engine to the machine frame. Make sure
fastener holes of the engine brackets are aligned
with the holes in the engine mounts.
D. Insert cap screw down through each engine
bracket and mount. Place spacer, snubbingwasher
and then flange nut on four (4) cap screws. Tighten
fasteners to secure engine to engine mounts.
5. Connect hydraulic transmissiondrive shaft toengine
(see Hydraulic Transmission Drive Shaft Installation in
the Serviceand Repairssectionof Chapter 4 -- Hydraulic System).
6. Connect all wire harness connectors to correct en-
gine components.
12.Ifnecessary, removeengine brackets(item27)from
engine.
Groundsmaster 4300--DPage 3 -- 14Kubota Diesel Engine
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