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General Information This Chapter gives information about specifications and repair of the diesel engine used in the Groundsmaster 4100--D. General maintenance procedures are described in your Operator’s Manual. Information on engine troubleshooting, testing, disassembly and reassembly is identified in the Kubota Workshop Manual, Diesel Engine, V2403--M--T--E3B that is included at the end of this section. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Kubota Workshop Manual, Diesel Engine, V2403--M--T--E3B. The use of some specialized test equipment is explained. However, the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility. Service and repair parts for Kubota engines are supplied through your Authorized <strong>Toro</strong> Distributor. If no parts list is available, be prepared to provide your distributor with the <strong>Toro</strong> model and serial number of your machine. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Stopping the Engine IMPORTANT: Before stopping the engine after mowing or full load operation, cool the turbo-charger by allowing the engine to run at low idle speed for 5 minutes. Failure to do so may lead to turbocharger trouble. Kubota Diesel Engine Page 3 - 2 Groundsmaster 4100--D
Specifications Item Make / Designation Bore Stroke Total Displacement cc (cu. in.) Description Kubota Model V2403--M--T--E3B: 4--Cycle, 4 Cylinder, Water Cooled, Turbocharged, Diesel Engine 3.43” (87.0 mm) 4.031” (102.4 mm) 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 Kubota Diesel Engine Direction of Rotation Fuel Fuel Capacity Fuel Injection Pump Injection Nozzle Governor Low Idle (no load) High Idle (no load) Engine Oil Engine Oil Viscosity Crankcase Oil Capacity Oil Pump Coolant Capacity Starter Alternator/Regulator Standard Alternator Optional Alternator Engine Dry Weight Counterclockwise (viewed from flywheel) Diesel or Biodiesel (up to B20) Fuel with Low or Ultra Low Sulfur Content 19.0 U.S. gallons (72 liters) Denso PFR 4M Type Mini Pump Denso OPD Mini Nozzle Centrifugal Mechanical 1450 + 50 RPM 2870 +50/--120 RPM API CH--4, CI--4 or higher See Operator’s Manual 10.0 U.S. Quarts (9.5 Liters) with Filter Trochoid Type 13 U.S. Quarts (12.3 Liters) 12 VDC, 2.0 kW 12 VDC 40 amp 90 amp 419 U.S. pounds (190 kg) Groundsmaster 4100--D Page 3 - 3 Kubota Diesel Engine
Page 1 and 2: Part No. 08162SL (Rev. A) Service M
Page 3 and 4: Table Of Contents Chapter 1 - Safet
Page 5 and 6: Table of Contents GENERAL SAFETY IN
Page 7 and 8: Maintenance and Service 1. Before s
Page 9 and 10: Safety and Instruction Decals Numer
Page 11 and 12: Chapter 2 Table of Contents Product
Page 13 and 14: Torque Specifications Recommended f
Page 15 and 16: Standard Torque for Dry, Zinc Plate
Page 17: Chapter 3 Kubota Diesel Engine Tabl
Page 21 and 22: Removal (Fig. 1) 1. Park machine on
Page 23 and 24: Removal (Fig. 5) CAUTION B The muff
Page 25 and 26: DANGER Because diesel fuel is highl
Page 27 and 28: Removal (Fig. 8) 1. Park machine on
Page 29 and 30: Engine Removal (Fig. 9) 1. Park mac
Page 31 and 32: 3. Slowly lower engine into the mac
Page 33 and 34: Coupler Removal (Fig. 16) NOTE: The
Page 35 and 36: Chapter 4 Hydraulic System Table of
Page 37 and 38: General Information Operator’s Ma
Page 39 and 40: Hydraulic Hose and Tube Installatio
Page 41 and 42: Adjustable Fitting (Fig. 8) 1. Make
Page 43 and 44: Hydraulic System This page is inten
Page 45 and 46: Traction Circuit: 4WD (Mow) The tra
Page 47 and 48: Traction Circuit: Transport (2WD) T
Page 49 and 50: Lower Cutting Deck A four section g
Page 51 and 52: Raise Cutting Deck A four section g
Page 53 and 54: Mow Circuit Hydraulic flow for the
Page 55 and 56: Hydraulic System This page is inten
Page 57 and 58: Steering Circuit A four section gea
Page 59 and 60: Engine Cooling Fan Circuit A four s
Page 61 and 62: Hydraulic Test Fitting Kit This kit
Page 63 and 64: Problem Traction power is lost or u
Page 65 and 66: Testing The most effective method f
Page 67 and 68: Procedure for Traction Circuit Char
Page 69 and 70:
Procedure for Traction Circuit Reli
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Procedure for Counterbalance Pressu
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Procedure for Rear Traction Circuit
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Procedure for Traction Circuit Redu
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Procedure for Cutting Deck Circuit
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Procedure for Cutting Deck Manifold
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Procedure for Cutting Deck Gear Pum
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Procedure for Cutting Deck Motor Ca
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Procedure for Steering Circuit Reli
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Procedure for Lift/Lower Circuit Re
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Procedure for Steering and Lift/Low
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Procedure for Engine Cooling Fan Ci
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Procedure for Engine Cooling Fan Ci
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Service and Repairs General Precaut
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Charge Hydraulic System NOTE: When
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NOTE: The front frame needs to be l
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Removal (Fig. 48) CAUTION The radia
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Removal (Fig 49) 1. Park machine on
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IMPORTANT: Use caution when clampin
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Hydraulic System This page is inten
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Removal (Fig. 53) 1. Park machine o
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Removal (Fig. 59) NOTE: The ports o
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4WD Manifold Service (Fig. 60) 1. M
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Removal (Fig. 61) 1. Read the Gener
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Filter Manifold Service (Fig. 62) F
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CAUTION The centering springs are u
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Disassembly (Fig. 68) 1. Pump oil o
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8. Remove and discard back--up gask
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Fan Drive Manifold Service (Fig. 76
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Cutting Deck Motor Removal 1. Park
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IMPORTANT: Mark the relative positi
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Removal (Fig. 85) NOTE: The ports o
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PTO Manifold Service (Fig. 86) For
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Disassembly (Fig. 89) 1. Plug all p
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Disassembly (Figs. 92 and 93) 1. Re
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Chapter 5 Electrical System Table o
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Special Tools Order special tools f
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Troubleshooting CAUTION Remove all
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Cutting Deck Operating Problems The
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Adjustments Wing Deck Position Swit
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Component Testing For accurate resi
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Warning Lights Engine Oil Pressure
Page 185 and 186:
Transport / 4WD Switch The transpor
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Seat Switch The seat switch is norm
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Hour Meter The hour meter is locate
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Start, Engine Shutdown, Seat, Alarm
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TEC -5002 Controller Groundsmaster
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Fuel Gauge The fuel gauge can be te
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Glow Controller The glow controller
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Dual Temperature Switch The dual te
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Traction Neutral Switch The tractio
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Fusible Links The Groundsmaster 410
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Cutting Deck Raise and Lower Switch
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Service and Repairs NOTE: For engin
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2. Conduct a hydrometer test of the
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Chapter 6 Axles, Planetaries and Br
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General Information Operator’s Ma
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3. Chock rear wheels and jack up fr
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This page is intentionally blank. A
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Removal (Fig. 6) 1. Park machine on
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NOTE: The planetary wheel drive ass
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This page is intentionally blank. A
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8. Remove cap screw and flange nut
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Bevel Gear Case and Axle Case The f
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Bevel Gear Case and Axle Case Insta
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9. Remove the bevel gear case/axle
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Axle Shafts The following procedure
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7. Secure the lock nut with the sta
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Differential Gear Inspection 1. Mea
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Pinion Gear to Ring Gear Engagement
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Chapter 7 Chassis Table of Contents
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Disassembly (Fig. 1) 1. Park machin
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CAUTION When changing attachments,
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Removal (Fig. 5) 1. Park machine on
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Disassembly (Fig. 8) 1. Disassemble
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NOTE: Most of the seat suspension c
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Removal 1. Park machine on a level
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Chapter 8 Cutting Deck Table of Con
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General Information CAUTION Never i
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This page is intentionally blank. C
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Removal (Fig. 1) 1. Position machin
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Removal (Fig. 6) 1. Position machin
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Cutting Deck Link Service Disassemb
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Installation (Fig. 13) 1. Position
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2. Install outer bearing spacer int
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Disassembly (Fig. 22) 1. Park machi
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Chapter 9 Foldout Drawings Table of
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CENTER DECK MANIFOLD COUNTERBALANCE
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CONTINUES FROM SHEET 1 CONTINUES FR
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CONTINUES TO SHEET 2 CONTINUES TO S
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CONTINUES TO SHEET 2 WHEN THE PTO S
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CONTINUES TO SHEET 2 CONTINUES TO S
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YELLOW GRAY YELLOW/BLACK VIOLET WHI
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FLOW DIVIDER SOLENOID Groundsmaster
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(STARTER) (STARTER) (STARTER) Groun
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BLUE GRAY VIOLET BLACK YELLOW GRAY
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