Toro greensmaster 3250 d service repair manual

Part No. 00062SL (Rev. H)
Service Manual
Greensmaster 3250−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
Greensmaster 3250−D.
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR’S MANUALS FOR OPERATING,
MAINTENANCE AND ADJUSTMENT INSTRUC-
TIONS. Space is provided in Chapter 2 of this book to
insert the Operator’s Manuals and Parts Catalogs for
your machine. Replacement Operator’s Manuals and
Parts Catalogs are available by sending complete Mod-
el and Serial Number to:
The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420−1196
The Toro Company reserves the right to change product
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-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
The Toro Company − 2000, 2003, 2004, 2005, 2006, 2007

Rev. H
Table Of Contents
Chapter 1 − Safety
Safety Instructions 1 − 2
. . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 1 − 5
. . . . . . . . . . . . . . . .
Chapter 2 − Product Records and Maintenance
Product Records 2 − 1
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 2 − 2
. . . . . . . . . . . . . . . .
Torque Specifications 2 − 3
. . . . . . . . . . . . . . . . . . . . . . .
Lubrication 2 − 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 2 − 8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 3 − Engine
Introduction 3 − 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3 − 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 3 − 4
. . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 3 − 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 3 − 8
. . . . . . . . . . . . . . . . . . . . . . . .
Briggs and Stratton, Vanguard/Daihatsu Repair Manual
for 3−Cylinder, Water−Cooled, Diesel Engines
Chapter 4 − Hydraulic System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematics 4 − 8
. . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Flow Diagrams 4 − 10
. . . . . . . . . . . . . . . . . . .
Special Tools 4 − 18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trouble Shooting 4 − 20
. . . . . . . . . . . . . . . . . . . . . . . . . .
Testing 4 − 23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 4 − 42
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
Eaton Gear Pumps, Repair Information, Series 26,
Model 26000, Multiple Gear Pumps
Eaton, Medium Duty Piston Pump, Repair Informa-
tion, Model 70160 Variable Displacement Piston
Pump
Ross Torqmotor TM MG, MF, MP, MB, ME, and MJ
Series Service Procedure (Service Manual
2704−003)
Chapter 5 − Electrical System
Electrical Schematics 5 − 2
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 5 − 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System Quick Checks 5 − 8
. . . . . . . . . . . . . .
Component Testing 5 − 9
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
Chapter 6 − Chassis
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 6 − 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
Chapter 7 − SPA and 4 Bolt Cutting Units
Introduction 7 − 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 7 − 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 7 − 9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
Chapter 7.1 − DPA Cutting Units
Specifications 7.1 − 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 7.1 − 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 7.1 − 5
. . . . . . . . . . . . . . . . . . . . . . . . . .
Setup and Adjustments 7.1 − 7
. . . . . . . . . . . . . . . . . . .
Service and Repairs 7.1 − 8
. . . . . . . . . . . . . . . . . . . . . .
Chapter 7.2 − Groomer (DPA Cutting Unit)
Specifications 7.2 − 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 7.2 − 3
. . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 7.2 − 4
. . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 7.2 − 6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 7.2 − 7
. . . . . . . . . . . . . . . . . . . . . .
Chapter 8 − Electrical Diagrams
Electrical Schematics 8 − 3
. . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagrams 8 − 9
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Harness Drawings 8 − 16
. . . . . . . . . . . . . . . .
Safety
Product
Records
and
Maintenance
Engine
Hydraulic
System
Electrical
System
Chassis
Cutting
Units
Electrical
Diagrams

Rev. H
Greensmaster 3250−D Page 1 − 1 Safety
Chapter 1
Safety
Table of Contents
SAFETY INSTRUCTIONS 2
. . . . . . . . . . . . . . . . . . . . . .
Before Operating 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
While Operating 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Service 4
. . . . . . . . . . . . . . . . . . . .
SAFETY AND INSTRUCTION DECALS 4
. . . . . . . . . .
Safety

Page 1 − 2
Safety
Safety Instructions
The GREENSMASTER 3250−D was tested and certi-
fied by TORO for compliance with the B71.4−1984 spec-
ifications of the American National Standards Institute.
Although hazard control and accident prevention par-
tially are dependent upon the design and configuration
of the machine, these factors are also dependent upon
the awareness, concern, and proper training of the per-
sonnel involved in the operation, transport, mainte-
nance, and storage of the machine. Improper use or
maintenance of the machine can result in injury or
death.
The safety alert symbol means
CA UTION, WARNING or DANGER
personal safety instruction. Read
and under stand the instruction because it has to
do with safety. Failure to comply with the instruc-
tion may result in personal injury.
WARNING
To reduce the potential for injury or death, comply
with the following safety instructions.
Before Operating
1. Read and understand the contents of this Opera-
tor’s Manual before starting and operating the machine.
Become familiar with all controls and know how to stop
quickly. A replacement manual is available by sending
complete Model and Serial Number to:
The Toro Company
Attn. Technical Publications
8111 Lyndale Avenue South
Minneapolis, Minnesota 55420−1196
2. Never allow children to operate the machine. Never
allow adults to operate it without proper instructions.
3. Become familiar with the controls, and know how to
stop the engine quickly.
4. Keep all shields, safety devices, and decals in
place. If a shield, safety device, or decal is defective, il-
legible, or damaged: repair or replace it before operating
the machine.
5. Always wear substantial shoes. Do not operate ma-
chine while wearing sandals, tennis shoes or sneakers.
Do not wear loose fitting clothing which could get caught
in moving parts and cause personal injury.
6. Wearing safety glasses, safety shoes, long pants
and a helmet is advisable and required by some local
safety and insurance regulations.
7. Make sure work area is clear of objects which might
be picked up and thrown by the reels.
8. Do not carry passengers on the machine. Keep ev-
eryone, especially children and pets, away from the
areas of operation.
9. Diesel fuel is flammable; handle it carefully.
A. Use an approved diesel container.
B. Do not remove cap from fuel tank when engine is
hot or running.
C. Do not smoke while handling diesel fuel.
D. Fill fuel tank outdoors and no higher than to the
bottom of filler neck. Do not overfill.
E. Wipe up any spilled fuel.

Rev. G
Greensmaster 3250−D Page 1 − 3 Safety
While Operating
10. Do not run the engine in a confined area without ad-
equate ventilation. Exhaust fumes are hazardous and
could be deadly.
11. Sit on the seat when starting and operating the ma-
chine.
12. Check the operation of the interlock switches daily
for proper operation (see Verify Interlock System Opera-
tion in Chapter 5 − Electrical System). Replace any mal-
functioning switches before operating the machine.
13. To start the engine:
A. Sit on the seat, make sure cutting units are dis-
engaged.
B. Verify that functional control lever is in neutral.
C. Verify that parking brake is set.
D. Proceed to start engine.
14. Using the machine demands attention, and to pre-
vent loss of control:
A. Mow only in daylight or when there is good artifi-
cial light.
B. Watch for holes or other hidden hazards.
C. Do not drive close to sand traps, ditches, creeks
or other hazards.
D. Reduce speed when making sharp turns. Avoid
sudden stops and starts.
E. Before backing up, look to the rear to be sure no
one is behind the machine.
F. Watch out for traffic when near or crossing
roads. Always yield the right−of−way.
G. Apply the service brakes when going downhill to
keep forward speed slow and to maintain control of
the machine.
15. Keep hands, feet and clothing away from moving
parts and the reel discharge area. The grass baskets
must be in place during operation of the reels or thatch-
ers for maximum safety. Shut the engine off before emp-
tying the baskets.
16. The GREENSMASTER 3250−D may exceed noise
levels of 85 dB(A) at the operator position. Ear protec-
tors are recommended, for prolonged exposure, to re-
duce the potential of permanent hearing damage.
17. Raise the cutting units when driving from one work
area to another.
18. Do not touch engine, muffler or exhaust pipe while
engine is running or soon after it is stopped because
these areas could be hot enough to cause burns.
19. If a cutting unit strikes a solid object or vibrates ab-
normally, stop immediately, turn engine off, wait for all
motion to stop and inspect for damage. A damaged reel
or bedknife must be repaired or replaced before opera-
tion is continued.
20. Before getting off the seat:
A. Make sure cutting units are disengaged.
B. Verify that functional control system is in neutral.
C. Set the parking brake.
D. Stop the engine and remove key from ignition
switch.
21. Traverse slopes carefully. Do not start or stop sud-
denly when traveling uphill or downhill.
22. Operator must be skilled and trained in how to drive
on hillsides. Avoid wet slopes. Failure to use caution on
slopes or hills may cause loss of control and vehicle to
tip or roll possibly resulting in personal injury or death.
23. If engine stalls or loses headway and cannot make
it to the top of a slope, do not turn machine around. Al-
ways back slowly straight down the slope.
24. DON’T TAKE AN INJURY RISK! When a person or
pet appears unexpectedly in or near the mowing area,
STOP MOWING. Careless operation, combined with
terrain angles, ricochets, or improperly positioned
guards can lead to thrown object injuries. Do not resume
mowing until area is cleared.
25. Whenever machine is left unattended, make sure
cutting units are fully raised and reels are not spinning,
key is removed from ignition switch and parking brake
is set.
Safety

Rev. H Greensmaster 3250−D
Page 1 − 4
Safety
Maintenance and Service
26. Before servicing or making adjustments to the ma-
chine, stop the engine, remove key from switch to pre-
vent accidental starting of the engine.
27. Be sure entire machine is in good operating condi-
tion. Keep all nuts, bolts, screws and hydraulic fittings
tight.
28. Make sure all hydraulic line connectors are tight,and
all hydraulic hoses and lines are in good condition be-
fore applying pressure to the system.
29. Keep body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pressure.
Use paper or cardboard, not hands, to search for leaks.
Hydraulic fluid escaping under pressure can have suffi-
cient force to penetrate skin and do serious damage. If
fluid is ejected into the skin it must be surgically removed
within a few hours by a doctor familiar with this form of
injury or gangrene may result.
30. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be re-
lieved by stopping engine and lowering cutting units and
attachments to the ground.
31. To reduce potential fire hazard, keep the engine
area free of excessive grease, grass, leaves and accu-
mulation of dirt. Never wash a warm engine or electrical
connections with water.
32. Check all fuel lines for tightness and wear on a regu-
lar basis, and tighten or repair as needed.
33. If the engine must be running to perform a mainte-
nance adjustment, keep hands, feet, clothing and any
other parts of the body away from the cutting units, at-
tachments and any moving parts. Keep everyone away.
34. Do not overspeed the engine by changing governor
settings. To assure safety and accuracy, have an Autho-
rized Toro Distributor check maximum engine speed
with a tachometer. Maximum governed engine speed
should be 2750 + 50 RPM.
35. Engine must be shut off before checking oil or ad-
ding oil to the crankcase.
36. If major repairs are ever needed or if assistance is
desired, contact an Authorized Toro Distributor.
37. At the time of manufacture, the GREENSMASTER
3250−D conformed to safety standards in effect for rid-
ing mowers. To make sure of optimum performance and
continued safety certification of the machine, use genu-
ine TORO replacement parts and accessories. Re-
placement parts and accessories made by other
manufacturers could be dangerous, and such use could
void the product warranty of The Toro Company.
38. When changing attachments, tires, or performing
other service, use correct blocks, hoists, and jacks.
Make sure machine is parked on a solid level floor such
as a concrete floor. Prior to raising the machine, remove
any attachments that may interfere with the safe and
proper raising of the machine. Always chock or block
wheels. Used jack stands or solid wood blocks to sup-
port the raised machine. If the machine is not properly
supported by blocks or jack stands, the machine may
move or fall, which may result in personal injury.
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
the traction unit. If any decal becomes illegible or dam-
aged, install a new decal. Part numbers are listed in your
Parts Catalog. Order replacement decals from your Au-
thorized Toro Distributor.

Rev. H
Greensmaster 3250−D Page 2 − 1 Product Records and Maintenance
Chapter 2
Product Records and Maintenance
Table of Contents
PRODUCT RECORDS 1
. . . . . . . . . . . . . . . . . . . . . . . . .
EQUIVALENTS AND CONVERSIONS 2
. . . . . . . . . . .
Decimal and Millimeter Equivalents 2
. . . . . . . . . . . .
U.S. to Metric Conversions 2
. . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS 3
. . . . . . . . . . . . . . . . . . .
Fastener Identification 3
. . . . . . . . . . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated, and
Steel Fasteners (Inch Series). 4
. . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated, and
Steel Fasteners (Metric Fasteners). 5
. . . . . . . . . .
Other Torque Specifications 6
. . . . . . . . . . . . . . . . . .
LUBRICATION 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Traction Unit 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single Point Adjust Cutting Unit 8
. . . . . . . . . . . . . . .
4−Bolt Cutting Unit 8
. . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE 8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Records
Insert a copy of the Operator’s Manual and Parts Cata-
log for your Greensmaster 3250−D at the end of this
chapter. Additionally, if any optional equipment or ac-
cessories have been installed to your machine, insert
the Installation Instructions, Operator’s Manuals and
Parts Catalogs for those options at the end of this chap-
ter.
Product
Records
and
Maintenance

0.09375
Page 2 − 2
Equivalents and Conversions

Torque Specifications
Recommended fastener torque values are listed in the
following tables. For critical applications, as determined
by Toro, either the recommended torque or a torque that
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 to all fasteners which
do not have a specific requirement identified in this Ser-
vice Manual. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (Loctite), degree of lubrication on the
fastener, presence of a prevailing torque feature, hard-
ness of the surface underneath the fastener’s head, or
similar condition which affects the installation.
As noted in the following tables, torque values should be
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread 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.
Measure the torque required to tighten the fastener until
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
Product
Records
and
Maintenance

Page 2 − 4
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Thread Size
Grade 1, 5,
8 with Thin
Height Nuts
SAE Grade 1 Bolts, Screws, Studs,
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
in−lb in−lb N−cm in−lb N−cm in−lb N−cm
# 6 − 32 UNC
10 + 2 13 + 2 147 + 23
15 + 2 170 + 20 23 + 2 260 + 20
# 6 − 40 UNF
10 + 2 13 + 2 147 + 23
17 + 2 190 + 20 25 + 2 280 + 20
# 8 − 32 UNC
13 + 2 25 + 5 282 + 30
29 + 3 330 + 30 41 + 4 460 + 45
# 8 − 36 UNF
13 + 2 25 + 5 282 + 30
31 + 3 350 + 30 43 + 4 485 + 45
# 10 − 24 UNC
18 + 2 30 + 5 339 + 56
42 + 4 475 + 45 60 + 6 675 + 70
# 10 − 32 UNF
18 + 2 30 + 5 339 + 56
48 + 4 540 + 45 68 + 6 765 + 70
1/4 − 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1125 + 100 140 + 15 1580 + 170
1/4 − 28 UNF 53 + 7 65 + 10 734 + 113 115 + 10 1300 + 100 160 + 15 1800 + 170
5/16 − 18 UNC 115 + 15 105 + 17 1186 + 169 200 + 25 2250 + 280 300 + 30 3390 + 340
5/16 − 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2540 + 280 325 + 30 3670 + 340
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 + 4 58 + 5
3/8 − 24 UNF 17 + 2 18 + 2 24 + 3 35 + 3 47 + 4 50 + 4 68 + 5
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 + 5 75 + 7 77 + 7 104 + 9
1/2 − 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 10 142 + 14
1/2 − 20 UNF 32 + 3 53 + 7 72 + 9 85 + 8 115 + 11 120 + 10 163 + 14
5/8 − 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 20 285 + 27
5/8 − 18 UNF 75 + 10 95 + 15 129 + 20 170 + 15 230 + 20 240 + 20 325 + 27
3/4 − 10 UNC 93 + 12 140 + 20 190 + 27 265 + 25 359 + 34 375 + 35 508 + 47
3/4 − 16 UNF 115 + 15 165 + 25 224 + 34 300 + 25 407 + 34 420 + 35 569 + 47
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 + 45 644 + 61 660 + 60 895 + 81
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
oil, graphite, 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-
mum proof load specified in SAE J429. The tolerance is
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.

Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
Thread Size
Class 8.8 Bolts, Screws, and Studs with
Regular Height Nuts
Class 10.9 Bolts, Screws, and Studs with
Regular Height Nuts
Thread Size Regular Height Nuts
(Class 8 or Stronger Nuts)
Regular Height Nuts
(Class 10 or Stronger Nuts)
M5 X 0.8 57 + 5 in−lb 640 + 60 N−cm 78 + 7 in−lb 885 + 80 N−cm
M6 X 1.0 96 + 9 in−lb 1018 + 100 N−cm 133 + 13 in−lb 1500 + 150 N−cm
M8 X 1.25 19 + 2 ft−lb 26 + 3 N−m 27 + 2 ft−lb 36 + 3 N−m
M10 X 1.5 38 + 4 ft−lb 52 + 5 N−m 53 + 5 ft−lb 72 + 7 N−m
M12 X 1.75 66 + 7 ft−lb 90 + 10 N−m 92 + 9 ft−lb 125 + 12 N−m
M16 X 2.0 166 + 15 ft−lb 225 + 20 N−m 229 + 22 ft−lb 310 + 30 N−m
M20 X 2.5 325 + 33 ft−lb 440 + 45 N−m 450 + 37 ft−lb 610 + 50 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
oil, graphite, 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
SAE J1199. The tolerance is approximately + 10% of the
nominal torque value.
Product
Records
and
Maintenance

Page 2 − 6
Other Torque Specifications
SAE Grade 8 Steel Set Screws
Thread Size
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 + 3 ft−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 + 5 in−lb
No. 8 − 32 UNC 30 + 5 in−lb
No. 10 − 24 UNC 38 + 7 in−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
Size
Threads per Inch
Baseline Torque*
Size
Type A Type B
Baseline Torque*
No. 6 18 20 20 + 5 in−lb
No. 8 15 18 30 + 5 in−lb
No. 10 12 16 38 + 7 in−lb
No. 12 11 14 85 + 15 in−lb
* Hole size, material strength, material thickness finish
must be considered when determining specific torque
values. All torque values are based on non−lubricated
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

Lubrication
Traction Unit
CAUTION
Before servicing or making adjustments to the
machine, stop engine and remove key from the
switch.
The traction unit has grease fittings that must be lubri-
cated regularly with No. 2 General Purpose Lithium
Base Grease. If machine is operated under normal
conditions, lubricate all bearings and bushings after ev-
ery 50 hours of operation. Lubricate fittings immediately
after every washing, regardless of the interval listed.
The traction unit bearings and bushings that must be lu-
bricated are: Rear wheel hub (1), Castor bearing (1),
Steering cylinder (2) (Fig. 3), Lift arms (3) (Fig. 4), Trac-
tion pedal pivot (1) (Fig. 5).
1. Wipe grease fitting clean so foreign matter cannot
be forced into the bearing or bushing.
2. Pump grease into the bearing or bushing.
3. Wipe up excess grease.
4. Apply grease to reel motor spline shaft and onto lift
arm when cutting unit is removed for service.
5. Apply a few drops of SAE 30 engine oil or spray lu-
bricant (WD 40) to all pivot points daily after cleaning.
Figure 3
Figure 4
Figure 5
Product
Records
and
Maintenance

Page 2 − 8
Single Point Adjust Cutting Unit
Each cutting unit has (7) grease fittings that must be lu-
bricated regularly with No. 2 General Purpose Lithium
Base Grease.
The grease fitting locations and quantities are: Bedknife
pivot (1), Reel bearings (2), and front and rear rollers (2
ea.).
IMPORTANT: Lubricating cutting units immediately
after washing helps purge water out of bearings and
increases bearing life.
1. Wipe each grease fitting with a clean rag.
IMPORTANT: Do not apply too much pressure or
grease seals will be permanently damaged.
2. Apply grease until pressure is felt against handle.
3. Wipe excess grease away.
Figure 6
4−Bolt Cutting Unit
Each cutting unit has (6) grease fittings that must be lu-
bricated regularly with No. 2 General Purpose Lithium
Base Grease.
The grease fitting locations and quantities are: Reel
bearings (2) and front and rear rollers (2 ea.).
IMPORTANT: Lubricating cutting units immediately
after washing helps purge water out of bearings and
increases bearing life.
1. Wipe each grease fitting with a clean rag.
IMPORTANT: Do not apply too much pressure or
grease seals will be permanently damaged.
2. Apply grease until pressure is felt against handle.
3. Wipe excess grease away.
Figure 7
Maintenance
Maintenance procedures and recommended service in-
tervals for the Greensmaster 3250−D are covered in the
Operator’s Manuals. Refer to those publications when
performing regular equipment maintenance.

Greensmaster 3250−D Page 3 − 1 Engine
Chapter 3
Engine
Table of Contents
INTRODUCTION 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION 4
. . . . . . . . . . . . . . . . . . . . .
Fuel Shutoff Valve 4
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Engine Oil 4
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fill Fuel Tank 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleed Fuel System 5
. . . . . . . . . . . . . . . . . . . . . . . . . .
Check Cooling System 6
. . . . . . . . . . . . . . . . . . . . . . .
Drain Water from Fuel Filter/Water Separator 6
. . .
ADJUSTMENTS 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust Alternator Belt 7
. . . . . . . . . . . . . . . . . . . . . . . .
Adjust Throttle Control 7
. . . . . . . . . . . . . . . . . . . . . . .
Adjust Idle Speed 7
. . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS 8
. . . . . . . . . . . . . . . . . . . . . .
Service Air Cleaner 8
. . . . . . . . . . . . . . . . . . . . . . . . . .
Change Engine Oil and Filter 9
. . . . . . . . . . . . . . . . .
Replace Fuel Filter 9
. . . . . . . . . . . . . . . . . . . . . . . . . .
Muffler and Air Cleaner 10
. . . . . . . . . . . . . . . . . . . . .
Muffler Removal and Installation 11
. . . . . . . . . . . . . .
Air Cleaner Removal and Installation 11
. . . . . . . . . .
Radiator 12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator Removal and Installation 13
. . . . . . . . . . . .
Fuel Tank 14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank Removal and Installation 15
. . . . . . . . . . .
Engine 16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Removal 17
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Installation 21
. . . . . . . . . . . . . . . . . . . . . . . . .
Clean Radiator and Screen 23
. . . . . . . . . . . . . . . . . .
BRIGGS STRATTON, VANGUARD/DAIHATSU REP-
AIR MANUAL FOR 3−CYLINDER, WATER−
COOLED, DIESEL ENGINES
Engine

Page 3 − 2
Engine
Introduction
This Chapter gives information about specifications,
maintenance, troubleshooting, testing, and repair of the
diesel engine used in the Greensmaster 3250.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
tools are described in the Briggs Stratton, Vanguard/
Daihatsu Repair Manual for 3−Cylinder, Water−Cooled,
Diesel Engines. The use of some specialized test equip-
ment is explained. However, the cost of the test equip-
ment and the specialized nature of some repairs may
dictate that the work be done at an engine repair facility.
Service and repair parts for Briggs Stratton, Vanguard/
Daihatsu engines are supplied through your local Briggs
and Stratton dealer or distributor. If no parts list is avail-
able, be sure to provide your distributor with the Toro
model and serial number.

Specifications
Item Description
Make / Designation Briggs and Stratton Vanguard/Daihatsu, Water−cooled, Diesel,
Model 522447
Number of Cylinders 3
Horsepower Governed to 14.5 + 0.5 HP @ 2600 RPM
Torque kg−m (ft−lb) 4.76 (34.5) @ 2300 RPM
Bore x Stroke mm (in.) 68 x 78 (2.68 x 3.07)
Total Displacement cc (cu. in.) 850 (51.8)
Compression Ratio 24.5:1
Firing Order 1− 2−3
Dry Weight (approximate) kg (lb.) 72 (159)
Fuel No. 2 Diesel per ASTM D975
Fuel Capacity liters (gallons) 22.7 (6.0)
Fuel Injection Pump VE (Bosch) type
Governor All speed type
Low Idle (no load) 1500 + 50 RPM
High Idle (no load) 2750 + 50 RPM
Engine Oil SAE 10W−30 CD, CE, CF, CF−4, or CG−4
Oil Pump Gear Driven Trochoid Type
Crankcase Oil Capacity liters (U.S. qt.) 3.3 (3.5) with filter
Water Pump Belt Driven Centrifugal Type
Cooling System Capacity liters (U.S. qt.) 3.1 (3.3)
Starter 12 VDC 1.2 KW
Alternator/Regulator 12 VDC 40 AMP
Engine

Page 3 − 4
Engine
General Information
DANGER
Because diesel fuel is flammable, use caution
when storing or handling it. Do not smoke while
filling the fuel tank. Do not fill fuel tank while en-
gine is running, hot, or when machine is in an en-
closed area. Always fill fuel tank outside and
wipe up any spilled diesel fuel before starting the
engine. Store fuel in a clean, safety−approved
container and keep cap in place. Use diesel fuel
for the engine only; not for any other purpose.
Fuel Shutoff Valve
This valve should be shut when removing the engine or
placing the unit in long term storage.
Figure 1
1. Fuel shut off (under the fuel tank)
1
Checking Engine Oil
IMPORTANT: Check level of oil every 8 operating
hours or daily.
Crankcase capacity is approximately 3.5 qts. (3.3 L)
with filter.
1. Position machine on a level surface.
2. Remove dipstick and wipe it with a clean rag. Push
dipstick into the tube and make sure it is seated fully. Re-
move dipstick from tube and check level of oil. If oil level
is low, remove filler cap from valve cover and add
enough oil to raise level to FULL mark on dipstick. Add
the oil slowly and check the level often during this pro-
cess. DO NOT OVERFILL.
3. The engine uses any high-quality detergent oil hav-
ing the American Petroleum Institute -API- “service clas-
sification” CD, CE, CF or CF−4 or CG−4 or higher.
Recommended viscosity (weight) is SAE 10W30.
Figure 2
1. Fill cap 2. dipstick
1
2
4. Install the filler cap and dipstick firmly in place.

Fill Fuel Tank
The engine runs on No. 2 diesel fuel. Fuel tank capacity
is approximately 6.0 gallons (22.7 L).
1. Clean area around fuel tank cap.
2. Remove fuel tank cap.
3. Fill tank to about one inch below the top of tank, (bot-
tom of the filler neck). Do not overfill. Install cap.
4. Wipe up any fuel that may have spilled to prevent a
fire hazard. Figure 3
1. Fuel cap
1
Bleed Fuel System
1. Position machine on a level surface. Make sure fuel
tank is at least half full.
2. Press primer button on top of fuel filter until resis-
tance is felt.
Note: It may be necessary to operate the primer but-
ton up to 30 times or more after starting the engine.
3. Start engine and continue to operate primer button
until engine runs smooth.
Figure 4
1. Fuel filter
2. Priming pump
3. Drain Plug
2
1
3
Check Cooling System
The cooling system is filled with a 50/50 solution of water
and ethylene glycol antifreeze. Check level of the cool-
ant at the beginning of each day before starting the en-
gine. Capacity of cooling system is approximately 3.6
qts. (3.4 L).
CAUTION
If engine has been running, pressurized hot cool-
ant can escape when the radiator cap is removed
and may cause burns.
1. Park machine on a level surface.
2. Check coolant level. Coolant should be between
lines on the reserve tank when engine is cold.
3. Install reserve tank cap.
Figure 5
1.Reserve tank
1
4. If the coolant level is low, remove reserve tank cap
and add a 50/50 mixture of water and permanent ethyl-
ene glycol antifreeze. Do not overfill.
Engine

Page 3 − 6
Engine
Drain Water from Fuel Filter/Water Separator
Any water accumulation should be drained from the fuel
filter/water separator before each use or when warning
light glows.
1. Position machine on a level surface and stop the en-
gine.
Note: Because the accumulated water will be mixed
with diesel fuel, drain the fuel filter into a suitable con-
tainer and dispose of properly.
2. Place a drain pan under the fuel filter.
3. Open the drain plug on the fuel filter/water separator
approximately one turn and drain any accumulated wa-
ter. If necessary, operate the priming pump to drain wa-
ter. Tighten the plug after draining.
4. Start the engine and make sure the warning light
goes out. Check for leaks.
Figure 6
1. Fuel filter
2. Priming pump
3. Drain Plug
2
1
3

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Adjustments
Adjust Alternator Belt
Make sure belt is properly tensioned to assure the prop-
er operation of the machine and prevent unnecessary
wear. On new belts, check tension after 8 hours of op-
eration.
The engine belt should be tensioned so it deflects 0.20
inch (5 mm) with a 2 to 3 lbf (9 to 13 N) load applied mid-
way between the crankshaft and alternator pulley.
1. Loosen bolts securing the alternator to the engine
and adjusting bracket.
2. Adjust belt to proper tension and tighten bolts.
Figure 7
1. Bolt 2. Belt
2
1
Adjust Throttle Control
Proper throttle operation is dependent upon proper ad-
justment of throttle control. Make sure throttle control is
operating properly.
1. Move remote throttle control lever to SLOW posi-
tion.
2. Loosen cable clamp screw securing cable to en-
gine.
3. Move cable until speed control lever contacts idle
speed screw
Figure 8
1. Throttle cable
2. Cable clamp
3. Speed control lever
4. Idle speed screw
2 1
3
4
Adjust Idle Speed (Fig. 8)
1. Move remote throttle control lever to SLOW posi-
tion.
2. Loosen lock nut on idle speed screw.
3. Adjust idle speed screw to obtain 1500 RPM.
4. Tighten lock nut.
Engine

Page 3 − 8
Engine
Service and Repairs
Service Air Cleaner
Service air cleaner filter every 200 hours (more fre-
quently in extreme dusty or dirty conditions).
1. Check air cleaner body and hoses for damage
which could possibly cause an air leak. Replace air
cleaner body if damaged.
2. Release latches securing the air cleaner cover to
the air cleaner body. Separate cover from the body.
Clean inside of air cleaner cover.
3. Gently slide filter out of the air cleaner body to re-
duce the amount of dust dislodged. Avoid knocking filter
against the air cleaner body.
4. Inspect filter. Discard filter if damaged. Do not wash
or reuse a damaged filter.
Washing Method
A. Prepare a solution of filter cleaner and water.
Soak filter element for about 15 minutes. Refer to
directions on the filter cleaner carton for complete
information.
B. After soaking the filter for 15 minutes, rinse it with
clear water. Maximum water pressure must not ex-
ceed 40 psi to prevent damage to the filter element.
Rinse filter from the clean side to dirty to side.
C. Dry filter element using warm, flowing air that
does not to exceed 160F (71C), or allow element
to air−dry. Do not use a light bulb to dry the filter ele-
ment because damage could result.
Compressed Air Method
CAUTION
Use eye protection such as goggles when using
compressed air.
A. Blow compressed air from the inside to the out-
side of the dry filter element. Do not exceed 100 psi
to prevent damage to the element.
B. Keep air hose nozzle at least 2 inches (5 cm)
from the filter. Move nozzle up and down while rotat-
ing the filter element. Inspect for holes and tears by
looking through the filter toward a bright light.
Figure 9
1. Air cleaner latches
2. Dust cup
3. Filter
1
3
2
5. Inspect new filter for shipping damage. Check seal-
ing end of the filter. Do not install a damaged filter.
6. Insert new filter properly into the air cleaner body.
Make sure filter is sealed properly by applying pressure
to the outer rim of the filter when installing. Do not press
on the flexible center of the filter.
7. Reinstall cover and secure latches.

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