Toro Groundsmaster 4000-D User manual

(Models 30448 and 30446)
Part No. 10176SL (Rev. A)
Service Manual
GroundsmasterR4000--D & 4010--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 4000--D (Model 30448) and 4010--D
(Model 30446).
REFER TO THE OPERATOR’S MANUAL FOR OPER-
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: ANOTE 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.
EThe Toro Company -- 2010, 2012
Groundsmaster 4010--D
Groundsmaster 4000--D

Groundsmaster 4000--D/4010--D
This page is intentionally blank.

Groundsmaster 4000--D/4010--D
Table Of Contents
Chapter 1 -- Safety
General Safety Instructions 1 -- 2..................
Jacking Instructions 1 -- 5.........................
Safety and Instruction Decals 1 -- 6................
Chapter 2 -- Product Records and Maintenance
Product Records 2 -- 1...........................
Maintenance 2 -- 1...............................
Equivalents and Conversions 2 -- 2................
Torque Specifications 2 -- 3.......................
Chapter 3 -- Kubota Diesel Engine
General Information 3 -- 2........................
Specifications 3 -- 3..............................
Service and Repairs 3 -- 4........................
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
V2403--M--T--E3B SERIES
Chapter 4 -- Hydraulic System
Specifications 4 -- 2..............................
General Information 4 -- 3........................
Hydraulic Schematic 4 -- 9........................
Hydraulic Flow Diagrams 4 -- 10...................
Special Tools 4 -- 26.............................
Troubleshooting 4 -- 30...........................
Testing 4 -- 36...................................
Adjustments 4 -- 70..............................
Service and Repairs 4 -- 72.......................
EATON MODEL 72400 SERVO CONTROLLED PIS-
TON PUMP 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..............................
Troubleshooting 5 -- 6............................
Adjustments 5 -- 17..............................
Electrical System Quick Checks 5 -- 18.............
Component Testing 5 -- 20........................
Service and Repairs 5 -- 47.......................
Chapter 6 -- Axles, Planetaries and Brakes
Specifications 6 -- 2..............................
General Information 6 -- 3........................
Service and Repairs 6 -- 4........................
Chapter 7 -- Chassis
General Information 7 -- 1........................
Service and Repairs 7 -- 2........................
Chapter 8 -- Cutting Decks
Specifications 8 -- 2..............................
General Information 8 -- 3........................
Troubleshooting 8 -- 4............................
Service and Repairs 8 -- 6........................
SafetyProduct Records
and Maintenance
Kubota
Diesel Engine
Hydraulic
System
Electrical
System
Axles, Planetaries
and Brakes
Chassis
Cutting
Decks

Groundsmaster 4000--D/4010--D
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Groundsmaster 4000--D/4010--D
Table Of Contents (Continued)
Chapter 9 -- Operator Cab
General Information 9 -- 2........................
Service and Repairs 9 -- 3........................
SANDEN SD COMPRESSOR SERVICE GUIDE
Chapter 10 -- Foldout Drawings
Hydraulic Schematic 10 -- 3.......................
Electrical Schematics 10 -- 4......................
Wire Harness Drawings 10 -- 9....................
OperatorFoldout
Drawings Cab

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

Groundsmaster 4000--D/4010--DPage 1 -- 2Safety
General Safety Instructions
TheGroundsmaster4000-Dand4010--Daretestedand
certified by Toro for compliance with existing safety
standards and specifications. Although hazard control
and accident prevention partially are dependent upon
the design and configuration of the machine, these fac-
tors are also dependent upon the awareness, concern
and proper training of the personnel involved in the op-
eration, 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 following safety instructions.
Before Operating
1. Review and understand the contents of the Opera-
tor’s Manual and Operator’s DVD before starting and
operatingthevehicle. Become familiar with the controls
and know how to stop the vehicle and engine quickly.
AdditionalcopiesoftheOperator’sManualareavailable
on the internet at www.Toro.com.
2. Keep all shields,safety devices and decals in place.
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 decks are DISENGAGED.
4. Since diesel 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.

Groundsmaster 4000--D/4010--D Page 1 -- 3 Safety
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 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 while
engineisrunningorsoonafteritisstopped.Theseareas
could be hot enough to cause burns.
5. Before getting off the seat:
A. Ensure that traction pedal is in neutral.
B. Apply the parking brake.
C. Disengage cutting decks and wait for blades to
stop.
D. Stop engine and remove key from switch.
E. Toro recommends that anytime the machine is
parked(short orlongterm), thecuttingdecks should
be lowered to the ground. This relieves hydraulic
pressurefromtheliftcircuitandeliminatestheriskof
the cutting decks unexpectedly lowering to the
ground.
F. Donotparkonslopesunlesswheelsarechocked
or blocked.
Safety

Groundsmaster 4000--D/4010--DPage 1 -- 4Safety
Maintenance and Service
1. Before servicing or making adjustments, lower
decks, stop engine, apply parking brake and remove
key from the ignition switch.
2. Make sure machine is in 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. Make sure all hydraulic connectors are tight and all
hydraulic hoses and lines are in good condition before
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. Before disconnecting or performing any work onthe
hydraulic system, all pressure in system must be re-
lievedbyloweringcutting deckstothegroundandstop-
ping engine.
7. Ifmajorrepairsareeverneededorassistance isde-
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
parts of the body away from cutting decks and other
moving parts. Keep bystanders away.
10.Do not overspeed the engine by changing governor
setting.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.
Avoid contact 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
tothe safetystandardsfor ridingmowers.Toassure op-
timumperformanceandcontinuedsafetycertificationof
the machine, use genuine Toro replacement parts and
accessories.Replacementpartsandaccessoriesmade
by other manufacturers may result in non-conformance
with the safety standards and the warranty may be
voided.
16.When changing attachments, tires or performing
other service, use correct blocks, hoists and jacks.
Make sure machine is parked on a solid level surface
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).
17.When welding on machine, disconnect all battery
cables to prevent damage to machine electronic equip-
ment. Disconnect negative battery cable first and posi-
tivecablelast.Also,disconnectwireharnessconnector
frombothof the TECcontrollersanddisconnect theter-
minal connector from the alternator. Attach welder
ground cable no more than two (2) feet (0.61 meters)
from the welding location.

Groundsmaster 4000--D/4010--D Page 1 -- 5 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 with the safe and proper raising of
themachine.Alwayschockorblockwheels.Use
jack stands 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 pre-
vent the machine from moving.
2. Positionjack securely undertheframe,justtothein-
side of the front tire. Jack front wheel off the ground.
3. Once the machine is raised, position jack stand un-
der the frame as close to the wheel as possible to sup-
port the machine.
Jacking the Rear End (Fig. 2)
1. Place jack securely under the center of rear axle.
2. Chock both front tires. Jack rear of machine off the
ground.
3. Once the machine is raised, use jack stands under
the axle to support the machine.
1. Front jacking point 2. Front tire
Figure 1
12
21
1. Rear axle jacking point 2. Rear tire
Figure 2
12
2
Safety

Groundsmaster 4000--D/4010--DPage 1 -- 6Safety
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
your Groundsmaster machine. If any decal becomes il-
legibleordamaged,installanewdecal.Decalpartnum-
bers are listed in your Parts Catalog.

Groundsmaster 4000--D/4010--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 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..........................
Product Records
Insert Operator’s Manuals and Parts Catalogs for your
Groundsmaster at the end of this chapter. Additionally,
if any optional equipment or accessories have been
installed to your machine, insert the Installation Instruc-
tions, Operator’s Manuals and Parts Catalogs for those
options at the end of this chapter.
Maintenance
Maintenanceproceduresandrecommendedservicein-
tervalsforyourGroundsmasterarecoveredintheOper-
ator’sManual.Refertothatpublicationwhenperforming
regular equipment maintenance.
Product Records
and Maintenance

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

Groundsmaster 4000--D/4010--D Page 2 -- 3 Product Records and Maintenance
Torque Specifications
Recommended fastener torque values are listed in the
followingtables.Forcriticalapplications,asdetermined
byToro,eithertherecommendedtorqueoratorquethat
is unique to the application is clearly identified and spe-
cified in this Service Manual.
These Torque Specifications for the installation and
tightening of fasteners shall apply toall fasteners which
donothave a specific requirementidentifiedin this Ser-
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.
Measurethetorquerequiredtotightenthefasteneruntil
the lines match up.
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
torquewrenchcalibration due totheeffective changeof
torquewrenchlength.Whenusingatorquewrenchwith
an offset wrench, multiply the listed torque recommen-
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 torque conversion factor for this torque
wrenchwiththisoffsetwrenchwouldbe 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 4000--D/4010--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 + 2169 + 23 23 + 3262 + 34
# 6 -- 40 UNF 10 + 213 + 2147 + 23 17 + 2192 + 23 25 + 3282 + 34
# 8 -- 32 UNC
1
3
+
2
2
5
+
5
2
8
2
+
3
0
29 + 3328 + 34 41 + 5463 + 56
# 8 -- 36 UNF 13 + 225 + 5282 + 30 31 + 4350 + 45 43 + 5486 + 56
#10--24UNC
1
8
+
2
3
0
+
5
3
3
9
+
5
6
42 + 5475 + 56 60 + 6678 + 68
#10--32UNF 18 + 230 + 5339 + 56 48 + 5542 + 56 68 + 7768 + 79
1/4 -- 20 UNC 48 + 753 + 7599 + 79 100 + 10 1130 + 113 140 + 15 1582 + 169
1/4 -- 28 UNF 53 + 765 + 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 + 216 + 222 + 330 + 341 + 443 + 558 + 7
3/8 -- 24 UNF 17 + 218 + 224 + 335 + 447 + 550 + 668 + 8
7/16 -- 14 UNC 27 + 327 + 337 + 450 + 568 + 770 + 795 + 9
7/16 -- 20 UNF 29 + 329 + 339 + 455 + 675 + 877 + 8104 + 11
1/2 -- 13 UNC 30 + 348 + 765 + 975 + 8102 + 11 105 + 11 142 + 15
1/2 -- 20 UNF 32 + 453 + 772 + 985 + 9115 + 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-
mumproofload specified in SAEJ429.The toleranceis
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.

Groundsmaster 4000--D/4010--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
t
N
u
t
s
Class 10.9 Bolts, Screws and Studs with
R
e
g
u
l
a
r
H
e
i
g
h
t
N
u
t
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 4000--D/4010--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 4000--D/4010--D Page 3 -- 1 Kubota Diesel Engine
Chapter 3
Kubota Diesel Engine
Table of Contents
SPECIFICATIONS 2.............................
GENERAL INFORMATION 3.....................
Operator’s Manual 3..........................
Stopping the Engine 3.........................
SERVICE AND REPAIRS 4......................
Air Filter System 4............................
Exhaust System 6............................
Fuel System 8................................
Check Fuel Lines and Connections 9...........
Empty and Clean Fuel Tank 9.................
Fuel Tank Removal 9........................
Fuel Tank Installation 9.......................
Radiator 10..................................
Engine 12....................................
Engine Removal 13..........................
Engine Installation 15........................
Spring Coupler 18.............................
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
03--M--E3B SERIES
Kubota
Diesel Engine

Groundsmaster 4000--D/4010--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 in (87.0 mm)
Stroke 4.031 in (102.4 mm)
Total Displacement 148.5 in3(2434 cc)
Firing Order 1 (closest to gear case end) -- 3 -- 4 (closest to flywheel end) -- 2
Combustion Chamber Spherical Type (E--TVCS)
Compression Ratio 23.0:1
Direction of Rotation Counterclockwise (viewed from flywheel)
Fuel Diesel or Biodiesel (up to B20) Fuel with Low or
Ultra Low Sulfur Content
Fuel Capacity 19 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) 1425 + 50 RPM
High Idle (no load) 2870 + 50/--120 RPM
Engine Oil API CH--4, CI--4 or higher
Engine Oil Viscosity See Operator’s Manual
Crankcase Oil Capacity 10 U.S. quarts (9.5 liters) with Filter
Oil Pump Trochoid Type
Coolant Capacity
Groundsmaster 4000--D 13 U.S. quarts (12.3 liters)
Groundsmaster 4010--D 17 U.S. quarts (16.1 liters)
Starter 12 VDC, 2.0 kW
Alternator/Regulator 12 VDC
Groundsmaster 4000--D 40 amp
Groundsmaster 4010--D 90 amp
Engine Dry Weight 419 U.S. pounds (190 kg)