Toro Lawn Mower 4100-D User manual

Category
Engine
Type
User manual

This manual is also suitable for

(Model 30413)
Part No. 08162SL (Rev. A)
Service Manual
Groundsmaster
R
4100--D
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 TOTHE OPERATOR’SMANUAL FOROPER-
ATING, MAINTENANCE AND ADJUSTMENT
INSTRUCTIONS. For reference, insert a copy of the
Operator’s Manual and Parts Catalog for your machine
into Chapter 2 of this service manual. Additional copies
of the Operator’s Manual and Parts Catalog are avail-
able on the internet at www.Toro.com.
TheToroCompanyreservestherighttochangeproduct
specifications or this publication without notice.
This safety symbol means DANGER, WARNING
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portantinstructionswhichmustbefollowedtopre-
vent damage to systems or components on the
machine.
E The To ro Company -- 2008, 2012
Groundsmaster 4100--D
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.............................
T roubleshooting 4 -- 28...........................
Testing 4 -- 31...................................
Adjustments 4 -- 60..............................
Service and Repairs 4 -- 61.......................
EATON MODEL 72400 SERVO CONTROLLED PIS-
TON PUMP REPAIR INFORMATION
EATON MODEL 74318 and 74348 PISTON MOTORS:
FIXED DISPLACEMENT, VALVE PLATE DESIGN
REPAIR INFORMATION
Chapter 5 -- Electrical System
General Information 5 -- 2........................
Special Tools 5 -- 3..............................
T roubleshooting 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........................
T roubleshooting 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
Hydraulic
System
Electrical
System
Axles, Planetaries
and Brakes
Cutting Deck Chassis
Foldout
Drawings
Groundsmaster 4100--D
This page is intentionally blank.
Groundsmaster 4100--D
Page 1 -- 1
Safety
Chapter 1
Safety
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..........
Safety
Groundsmaster 4100--D
Page 1 -- 2
Safety
General Safety Instructions
TheGROUNDSMASTER 4100-D wastested andcerti-
fied by TORO for compliance with existing safety stan-
dards 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 opera-
tion, transport, maintenance and storage of the ma-
chine.Improperuseormaintenanceofthemachinecan
resultininjuryordeath.Toreducethepotentialforinjury
or death, comply with the following safety instructions.
WARNING
To reduce the potential for injury or death,
comply with the f ollowing safety instructions.
Before Operating
1. Review and understand the contents of the Opera-
tor’s Manual and Operator’s DVD before s tarting and
operatingthe vehicle.Becomefamiliar withthe controls
and know how to stop the vehicle and engine quickly.
AdditionalcopiesoftheOperator’sManualareavailable
on the internet at www.Toro.com.
2. Keepall shields,s afety devices anddecals in place.
Ifashield,safetydeviceordecalisdefective,illegibleor
damaged, repair or replace it before operating the ma-
chine.Alsotightenanyloosenuts,boltsorscrewstoen-
sure 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.
4. Sincediesel fuel is highly flammable,handle it care-
fully:
A. Use an approved fuel container.
B. Donotremovefueltankcapwhileengineishotor
running.
C. Do not smoke while handling fuel.
D. Fillfueltankoutdoorsandonlytowithinaninchof
the top of the tank,not the filler neck. Do not overfill.
E. Wipe up any spilled fuel.
While Operating
1. Sit on the seat when starting and operating the ma-
chine.
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. Afterengineisstarted,releaseparkingbrakeand
keepfootofftractionpedal. Machinemustnotmove.
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.
3. Do not run engine in a confined area without ade-
quate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
4. Do not touch engine, muffler or exhaust pipe w hile
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 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 c utting deck should
be lowered to the ground. This relieves pressure
from the lift circuit and eliminates the risk of the cut-
ting deck unexpectedly lowering to the ground.
F. Donotparkonslopesunlesswheelsarechocked
or blocked.
Groundsmaster 4100--D
Page 1 -- 3
Safety
Maintenance and Service
1. Beforeservicingormakingadjustments,lowerdeck,
stop engine, apply parking brake and remove key from
the switch.
2. Makesure machine isin safeoperating condition by
keeping all nuts, bolts and screws tight.
3. Never store the machine or fuel container inside
wherethereisanopenflame,suchasnearawaterheat-
er or furnace.
4. Makesureall hydraulicline connectorsare tightand
all hydraulic hoses and lines are in good condition be-
fore applying pressure to the system.
5. Keepbodyandhandsawayfrompinholeleaksinhy-
drauliclinesthatejecthighpressurehydraulicfluid.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
mustbesurgicallyremovedwithinafewhoursbyadoc-
tor familiar with this form of injury or gangrene may re-
sult.
6. Beforedisconnecting or performing anyworkon the
hydraulic system, all pressure in system must be re-
lieved by stopping engine and lowering cutting deck to
the ground.
7. Ifmajor repairsare everneeded orassistanceis de-
sired, 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. Ifenginemustberunningtoperformmaintenanceor
an adjustment, keep hands, feet, clothing and other
partsofthebodyawayfromcuttingdeckandothermov-
ing parts. Keep bystanders away.
10.Do not overspeed the engine by changing governor
setting.Toassuresafetyandaccuracy,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 andclothing. 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 standardsforridingmowers.To assureop-
timumperformanceandcontinuedsafetycertificationof
the machine, use genuine Toro replacement parts and
accessories.Replacementpartsandaccessoriesmade
by othermanufacturers may result innon-conformance
with the safety s tandards 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
suchasaconcretefloor.Priortoraisingthemachine,re-
move 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 sup-
ported by jack stands, the machine may move or fall,
whichmayresultinpersonalinjury(seeJackingInstruc-
tions in this chapter).
Safety
Groundsmaster 4100--D
Page 1 -- 4
Safety
Jacking Instructions
CAUTION
When changing attachments, tires or perform-
ing other service, use correct jacks and sup-
ports. 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 withthe safe and proper raisingof
themachine.Alwayschockorblockwheels.Use
jackstands to supportthe raised machine.Ifthe
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 pre-
vent the machine from moving.
2. Positionjacksecurely undertheframe,justtothein-
side of the front tire. Jack front wheel off the ground.
3. Once the machine is raised, position suitable jack
standunder theframeas closeto thewheelaspossible
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. Oncethemachineisraised,usesuitablejackstands
under the rear axle to support the machine.
1. Frame jacking point 2. Front tire
Figure 1
1
2
2
1
1. Rear axle jacking point 2. Rear tire
Figure 2
1
2
2
Groundsmaster 4100--D
Page 1 -- 5
Safety
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
theGroundsmaster4100--D.Ifanydecalbecomesilleg-
ible or damaged, install a new decal. Decal part num-
bers are listed in your Parts Catalog.
Safety
Groundsmaster 4100--D
Page 1 -- 6
Safety
This page is intentionally blank.
Rev. A
Groundsmaster 4100--D Page 2 -- 1 Product Records and Maintenance
Chapter 2
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 To rque 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.........................
Product Records
Insert Operator’s Manual and Parts Catalog for your
Groundsmaster4100--Dattheendofthischapter.Refer
to Operator’s Manual for recommended maintenance
intervals. Additionally, insert Installation Instructions,
Operator’s Manuals and Parts Catalogs for any acces-
sories that have been installed on your Groundsmaster
at the end of this section.
Maintenance
Maintenanceproceduresandrecommendedservicein-
tervals for the Groundsmaster 4100--D are covered in
the Operator ’s Manual. Refer to that publication when
performing regular equipment maintenance. Several
maintenanceprocedureshavebreak--inintervalsidenti-
fiedintheO perator’sManual.RefertotheEngineOper-
ator’s Manual for additional engine specific
maintenance procedures.
Product Records
and Maintenance
0.09375
Groundsmaster 4100--DPage 2 -- 2Product Records and Maintenance
Equivalents and Conversions
Rev. A
Groundsmaster 4100--D Page 2 -- 3 Product Records and Maintenance
Torque Specifications
Recommended fastener torque values are listed in the
following tables.For criticalapplications,as determined
byToro,eithertherecommendedtorqueoratorquet hat
is unique to the application is clearly identified andspe-
cified in this Service Manual.
These Torque Specifications for the installation and
tightening offasteners shall apply to allfasteners which
do nothave aspecific requirement identifiedin thisSer-
vice 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’sheadorsimilarconditionwhichaffectsthe
installation.
Asnotedinthefollowingtables,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 en-
gagement, etc.
The standard method of verifying torque shall be per-
formed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measurethetorquerequiredto tightenthefasteneruntil
thelinesmatchup.
Fastener Identification
Figure 1
Grade 1 Grade 5 Grade 8
Inch Series Bolts and Screws
Figure 2
Class 8.8 Class 10.9
Metric Bolts and Screws
Using a Torque Wrench with an Offset Wrench
Useofanoffsetwrench(e.g.crowfootwrench)willaffect
torquewrench calibrationdue tothe effective changeof
torque wrenchlength.When usingatorquewrenchwith
an offset wrench, multiply the listed torque r ecommen-
dation 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 recommen-
dation.
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”.
The calculated t orque conversion factor for this torque
wrenchwith thisoffsetwrench wouldbe 18/19 =0.947.
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.
Figure 3
(effective length of
torque wrench)
TORQUE CONVERSION FACTOR = A / B
A
B
(effective length of torque
Torque wrenchOffset wrench
wrench + offset wrench)
Product Records
and Maintenance
Groundsmaster 4100--DPage 2 -- 4Product Records and Maintenance
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Thread Size
Grade 1, 5 &
8withThin
Height Nuts
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)
SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
in--lb in--lb N--cm in--lb N--cm in--lb N--cm
# 6 -- 32 UNC
1
0
+
2
1
3
+
2
1
4
7
+
2
3
15 + 2 169 + 23 23 + 3 262 + 34
# 6 -- 40 UNF
10 + 2 13 + 2 147 + 23
17 + 2 192 + 23 25 + 3 282 + 34
# 8 -- 32 UNC
1
3
+
2
2
5
+
5
2
8
2
+
5
6
29 + 3 328 + 34 41 + 5 463 + 56
# 8 -- 36 UNF
13 + 2 25 + 5 282 + 56
31 + 4 350 + 45 43 + 5 486 + 56
#10--24UNC
1
8
+
2
3
0
+
5
3
3
9
+
5
6
42 + 5 475 + 56 60 + 6 678 + 68
#10--32UNF
18 + 2 30 + 5 339 + 56
48 + 5 542 + 56 68 + 7 768 + 79
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
ft--lb ft--lb N--m ft--lb N--m ft--lb N--m
3/8 -- 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 5 58 + 7
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: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the mini-
mumproof loadspecifiedin SAEJ429.The toleranceis
approximately +
10% of the nominal torque value. Thin
height nuts include jam nuts.
Groundsmaster 4100--D Page 2 -- 5 Product Records and Maintenance
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)
T
h
r
e
a
d
S
i
z
e
Class 8.8 Bolts, Screws and Studs with
R
e
g
u
l
a
r
H
e
i
g
h
N
u
s
Class 10.9 Bolts, Screws and Studs with
R
e
g
u
l
a
r
H
e
i
g
h
N
u
s
Thread Size Regular Height Nuts
(Class 8 or Stronger Nuts)
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: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAEJ1199.Thetoleranceisapproximately+
10%ofthe
nominal torque value.
Product Records
and Maintenance
Groundsmaster 4100--DPage 2 -- 6Product Records and Maintenance
Other Torque Specifications
SAE Grade 8 Steel Set Screws
T
h
r
e
a
d
S
i
z
e
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
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
Wheel Bolts and Lug Nuts
Thread Size
Recommended Torque**
7/16 -- 20 UNF
Grade 5
65 + 10 ft--lb 88 + 14 N--m
1/2 -- 20 UNF
Grade 5
80 + 10 ft--lb 108 + 14 N--m
M12 X 1.25
Class 8.8
80 + 10 ft--lb 108 + 14 N--m
M12 X 1.5
Class 8.8
80 + 10 ft--lb 108 + 14 N--m
** For steel wheels and non--lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread
S
i
z
e
Threads per Inch
B
a
s
e
l
i
n
e
T
o
r
q
u
e
*
Size
Type A Type B
Baseline Torque
*
No. 6 18 20 20 + 5in--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,materialthicknessandfin-
ish must be considered when determining specific
torquevalues.Alltorquevaluesarebasedonnon--lubri-
cated fasteners.
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
Groundsmaster 4100--D Page 3 -- 1 Kubota Diesel Engine
Chapter 3
Kubota Diesel Engine
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
Kubota
Diesel Engine
Groundsmaster 4100--DPage 3 -- 2Kubota Diesel Engine
General Information
ThisChaptergivesinformationaboutspecificationsand
repair of the diesel engine used in the Groundsmaster
4100--D.
Generalmaintenanceproceduresaredescribedinyour
Operator’sManual.Informationonenginetroubleshoot-
ing,testing,disassemblyandreassemblyisidentifiedin
the Kubota Workshop Manual, Diesel Engine,
V2403--M--T--E3Bthatis includedattheend ofthissec-
tion.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
tools are described in the Kubota Workshop Manual,
DieselEngine,V2403--M--T--E3B.Theuseofsomespe-
cialized test equipment is explained. However, the cost
of the test equipment and the specialized nature of
somerepairsmaydictatethattheworkbedoneatanen-
gine repair facility.
Service and repair parts for Kubota engines are sup-
plied through your Authorized Toro Distributor. If no
partslistisavailable,bepreparedtoprovideyourdistrib-
utor with the Toro model and serial number of your ma-
chine.
Operators Manual
The Operator’s Manual provides information r egarding
the operation, general maintenance and maintenance
intervalsforyourGroundsmastermachine.Refertothat
publicationforadditionalinformationwhenservicingthe
machine.
Stopping the Engine
IMPORTANT: Before stopping the engine after
mowing or full load operation, cool the turbo-char-
ger by allowing the engine to run at low idle speed
for 5 minutes. Failure to do so may lead to turbo-
charger trouble.
Groundsmaster 4100--D Page 3 -- 3 Kubota 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 in
3
(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
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)
Kubota
Diesel Engine
Groundsmaster 4100--DPage 3 -- 4Kubota Diesel Engine
Service and Repairs
Air Filter System
Figure 1
1. Air cleaner hose
2. Hose clamp
3. Air cleaner assembly
4. Indicator
5. Air cleaner strap
6. Lock nut (2 used)
7. Hose clamp
8. Air cleaner hose
9. Hose clamp
10. Cap screw (2 used)
11. Flat washer (4 used)
12. Spring (2 used)
13. Flat washer (2 used)
14. Cap screw (2 used)
15. Adapter
16. Lock nut (2 used)
17. Flat washer (2 used)
VACUATOR
DIRECTION
FRONT
RIGHT
8
1
3
4
5
6
9
7
10
2
11
11
12
13
14
15
16
17
12 to 15 in--lb
(1.4 to 1.6 N--m)
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Toro Lawn Mower 4100-D User manual

Category
Engine
Type
User manual
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