Toro Bio-Diesel Kit, 2006 and Before Daihatsu-Powered Z Master Riding Mower Installation guide

Brand: Toro

Model: Bio-Diesel Kit, 2006 and Before Daihatsu-Powered Z Master Riding Mower

Type: Installation guide

FormNo.3360-694RevA

Bio-DieselFuelKit

2006andBeforeDaihatsu-PoweredZMasterRidingMowers

ModelNo.115–3563

InstallationInstructions

Afterthiskitisinstalled,thismachinecanusea

biodieselblendedfuelofuptoB20(20%biodiesel,80%

petrodiesel).Thepetrodieselportionshouldbelowor

ultralowsulfur.

Fuelisharmfulorfatalifswallowed.Long-term

exposuretovaporscancauseseriousinjuryand

illness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor

conditioneropening.

•Keepfuelawayfromeyesandskin.

Incertainconditions,fuelisextremely

ammableandhighlyexplosive.Areor

explosionfromfuelcanburnyouandothers

andcandamageproperty.

•Wipeupanyfuelthatspills.

•Neverllthefueltankinsideanenclosed

trailer.

•Neversmokewhenhandlingfuel,andstay

awayfromanopenameorwherefuel

fumesmaybeignitedbyaspark.

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

Qty.

Use

Fuelselectorvalvewithhoses1

Installthenewfuelselectorvalve.

Nopartsrequired

–

Removetheexistingwaterseparator

Mountingplate1

Locknut(1/4inch)

Fuellterclamp

Bolt(5/16x1-3/4inches)

Bolt(5/16x3/4inch)

Locknut(5/16inch)

Waterseparator1

Installthenewwaterseparator.

Hose1

Hoseclamp8

J-clamp1

Plastictie6

Installingandconnectingthefuelhoses.

Lowsulfurdecal

Fuelcap2

Dieseldecal1

Installthedecalsandfuelcaps.

Nopartsrequired

–

Verifytheconnections.

8111LyndaleAvenueSouth

Bloomington,MN55420

Registeratwww.Toro.com.

OriginalInstructions(EN)

PrintedintheUSA.

AllRightsReserved

InstallingtheNewFuel

SelectorValve

Partsneededforthisprocedure:

1Fuelselectorvalvewithhoses

Procedure

Important:Allowtheenginetocoolbefore

installingthiskit.

1.Drivethemachinetoawellventilatedareaaway

fromanopenameorwherefuelfumesmaybe

ignitedbyaspark.

2.Disengagethepowertakeoff(PTO)andsetthe

parkingbrake.

3.Turnofftheengine,removethekey,andwaitforall

movingpartstostopbeforeleavingtheoperating

position.

4.Disconnectthenegativebatterycablefromthe

battery.

5.Closethefuelselectorvalve.

6.Allowtheenginetocoolbeforeinstallingthiskit.

7.Tilttheseatforwardandremovethefrontengine

panel(Figure1).

Figure1

1.Frontenginepanel2.Knob

8.Todrainthefueltank,placeacleancontainerunder

thefrontfueltankconnection,removethefuelhose

fromthefrontconnectionorcutthefuellineand

directthefuellineintothecontainer(Figure2).

9.Allowthefueltodrainintothecontainerandwipe

upanyspilledfuel.Ensurethefuellineisremoved

fromthetankconnection(Figure2).

10.Drainthefuelfromtheoppositetank.

Figure2

1.Righthandfueltank

shown

3.Frontfueltankconnection

2.Rearfueltankconnection

11.Followthefuelhosesfromtheexistingselector

valveandremovethehosefromthefuellterand

thefueltanks.

12.Removetheexistingfuelhosefromtheengineand

removetheexistingfuellterfromthemachine.

13.Removetheexistingfuelselectorvalve.Referto

Figure3.Savetheexistinghardware.

14.Usingthepreviouslyremovedhardware,installthe

newfuelselectorvalve(Figure3).

Figure3

1.Existingnut

3.Newfuelselectorvalve

2.Existingwasher

RemovingtheExistingWater

Separator

NoPartsRequired

Procedure

Important:Allowtheenginetocoolbefore

installingthiskit.

1.Tilttheseatforwardandremovethefrontengine

panel(Figure4).

2.Closethefuelselectorvalve.

Figure4

1.Frontenginepanel2.Knob

3.Locatethehosebetweenthewaterseparatorandthe

fuelselectorvalve.Removethefuelhosefromthe

fuelselectorvalve(Figure5).

4.Locatethehosebetweenthewaterseparatorandthe

fuelselectorvalve.Removethefuelhosefromthe

theengine(Figure5).Rememberthelocationwhere

thefuelhosewasconnectedtotheengine.

5.Removetheexistingwaterseparatorfromthe

machine.

Figure5

1.Fuelhosefromthe

separatortotheengine

(makenotewherethe

connectionisonthe

engine)

3.Existingwaterseparator

2.Hosefromfuelselector

valve

4.Fuelselectorvalve

InstallingtheNewWater

Separator

Partsneededforthisprocedure:

1Mountingplate

Locknut(1/4inch)

Fuellterclamp

Bolt(5/16x1-3/4inches)

Bolt(5/16x3/4inch)

Locknut(5/16inch)

1Waterseparator

Procedure

1.Removetheexistinghardwarefromtheenginestrap

(Figure6).

2.Installthemountingbrackettotheenginestrapwith

thepreviouslyremovedhardware(Figure6).

3.Installthewaterseparatorintothefuellterclamp

andinstallittothemountingbracketwithabolt

(5/16x1-3/4inches),abolt(5/16x3/4inch),and

2locknuts(5/16inch)(Figure6).

Figure6

1.Locknut(5/16inch)7.Bolt(5/16x1-3/4inches)

2.J-clamp8.Mountingplate

3.Existinglocknut

9.Fuellterbracket

4.Existingwasher10.Waterseparator

5.Existingbolt11.Enginestrap

6.Bolt(5/16x3/4inch)

InstallingandConnectingthe

FuelHoses

Partsneededforthisprocedure:

1Hose

8Hoseclamp

1J-clamp

6Plastictie

Procedure

1.Routethefuellterandfuelhosetowardsthefuel

selectorvalve.Makesurenopartsorhosesare

touchingthemachineinareasthatwillgethot.

2.RemovetheexistinghardwareandintalltheJ-clamp

totheengineframe(Figure6andFigure7).

3.Installthefuelhoseconnectedtothefuellterinto

theJ-clamp(Figure7).

4.Installthenewfuelhoseontofuelselectorvalvewith

ahoseclamp(Figure7).

Figure7

1.Existinglocknut6.Fuelselectorvalve

2.J-clamp

7.Fuellter

3.Engineframe

8.Fuelhose

4.Existingwasher9.Hoseclamp

5.Existingbolt

5.Installthenewfuelhosetothewaterseparatorand

totheenginefuelconnectionwith2hoseclamps

(Figure8).Theconnectiontotheengineisthe

samepositionasthefuelhosethatwaspreviously

removed.

Figure8

1.Hoseclamp3.Waterseparator

2.Newfuelhose,connect

thisendtotheenginefuel

intake

6.Installtheshorthosetothefrontrighthandfuel

tankconnection(Figure9).

7.Installthelongerhosetotherearrighthandfuel

tankconnection(Figure9).

Figure9

1.Righthandfueltank

4.Longhose

2.Rearfueltankconnection5.Frontfueltankconnection

3.Hoseclamp

6.Shorthose

8.Installthelongerfuelhosetothefrontlefthand

fueltankconnection.SeeFigure10.forthecorrect

hoses.

9.Installtheshorthosetothebacklefthandfueltank

connection(Figure10).

Figure10

1.Lefthandfueltank4.Shorthose

2.Rearfueltankconnection

5.Longhose

3.Hoseclamp

6.Frontfueltankconnection

10.Installtheplastictiestosecurethehosesfrom

touchinganyhotpartsofthemachineorrubbing

againstthemachine.

InstallingtheDecalsandFuel

Caps

Partsneededforthisprocedure:

Lowsulfurdecal

2Fuelcap

1Dieseldecal

Procedure

1.Lowertheenginehood.

2.Removetheexistingdecaloneachside.

3.Installalowsulfurdecaloneachsideoftheengine

hood.SeeFigure4forthecorrectposition.

G008099

Figure11

1.Enginehood

2.Lowsulfurdecal

4.Cleantheexistingfrontdecalandtheareaaroundit

andletitdry(Figure12).

5.Installthenewdieseldecalovertheexistingone.

SeeFigure12.

G008999

Figure12

1.Dieseldecal

6.Removebothexistingfuelcapsandreplacethem

withthenewfuelcaps(Figure13).

G008998

Figure13

1.Newfuelcap

VerifyingtheConnections

NoPartsRequired

Procedure

1.Openthefuelselectorvalve.

2.Openthewaterseparatordrainvalveuntilfuelstarts

todrainoutandclosethevalve(Figure14).

3.Ensuretherearenoleaksatthefuelhose

connections.

4.Installthenegativebatterycableontothebattery.

5.Starttheengineandensuretherearenoleaks.

Figure14

1.Waterseparator

3.Rightsideofmachine

2.Drainvalve

Operation

AddingFuel

Afterthiskitisinstalled,thismachinecanusea

biodieselblendedfuelofuptoB20(20%biodiesel,

80%petrodiesel).Thepetrodieselportionshouldbe

loworultralowsulfur.

Observethefollowingprecautions:

•Thebiodieselportionofthefuelmeetspecication

ASTMD6751orEN14214.

•TheblendedfuelcompositionshouldmeetASTM

D975orEN590.

•Paintedsurfacesmaybedamagedbybiodiesel

blends.

•UseB5(biodieselcontendof5%)orlesserblend

incoldweather.

•Monitorseals,hoses,gasketsincontactwithfuelas

theymaybedegradeovertime.

•Fuellterpluggingmaybeexpectedforatimeafter

convertingtobiodieselblends.

•Contactyourdistributorifyouwishformore

informationonbiodiesel.

Purchasefuelinquantitiesthatcanbeusedwithin

30daystoensurefuelfreshness.

Usesummergradedieselfuel(No.2-D)attemperatures

above20°F(-7°C)andwintergradedieselfuel(No.

1-DorNo.1-D/2-Dblend)below20°F(-7°C).Useof

wintergradedieselfuelatlowertemperaturesprovides

lowerashpointandpourpointcharacteristics,

thereforeeasingstartabilityandlesseningchances

ofchemicalseparationofthefuelduetolower

temperatures(waxappearance,whichmaypluglters).

Useofsummergradedieselfuelabove20°F(-7°C)will

contributetowardlongerlifeofthepumpcomponents.

Important:Donotusekeroseneorgasoline

insteadofdieselfuel.Failuretoobservethis

cautionwilldamagetheengine.

Incertainconditions,fuelisextremely

ammableandhighlyexplosive.Areor

explosionfromfuelcanburnyouandothers

andcandamageproperty.

•Fillthefueltankoutdoors,inanopenarea,

whentheengineiscold.Wipeupanyfuel

thatspills.

•Neverllthefueltankinsideanenclosed

trailer.

•Donotllthefueltankcompletelyfull.Add

fueltothefueltankuntilthelevelis1/4to

1/2inch(6to13mm)belowthebottomof

thellerneck.Thisemptyspaceinthetank

allowsfueltoexpand.

•Neversmokewhenhandlingfuel,andstay

awayfromanopenameorwherefuel

fumesmaybeignitedbyaspark.

•Storefuelinanapprovedcontainerandkeep

itoutofthereachofchildren.Neverbuy

morethana30-daysupplyoffuel.

•Alwaysplacefuelcontainersontheground

awayfromyourvehiclebeforelling.

•Donotllfuelcontainersinsideavehicle

oronatruckortrailerbedbecauseinterior

carpetsorplastictruckbedlinersmay

insulatethecontainerandslowthelossof

anystaticcharge.

•Whenpractical,removegas-powered

equipmentfromthetruckortrailerand

refueltheequipmentwithitswheelsonthe

ground.

•Ifthisisnotpossible,thenrefuelsuch

equipmentonatruckortrailerfroma

portablecontainer,ratherthanfromafuel

dispensernozzle.

•Ifafueldispensernozzlemustbeused,keep

thenozzleincontactwiththerimofthefuel

tankorcontaineropeningatalltimesuntil

fuelingiscomplete.

Fuelisharmfulorfatalifswallowed.Long-term

exposuretovaporscancauseseriousinjuryand

illness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor

conditioneropening.

•Keepgasawayfromeyesandskin.

FillingtheFuelTank

1.Shuttheengineoffandsettheparkingbrake.

2.Cleanaroundeachfueltankcapandremovethe

cap.Addfueltobothfueltanks,untilthelevelis

1/4to1/2inch(6to13mm)belowthebottomof

thellerneck.Thisspaceinthetankallowsthefuel

toexpand.Donotllthefueltankscompletelyfull.

3.Installfueltankcapssecurely.Wipeupanyfuelthat

mayhavespilled.

4.Ifpossible,llthefueltankaftereachuse.Thiswill

minimizepossiblebuildupofcondensationinside

thefueltank.

Maintenance

ServicingtheFuelFilter

DrainingtheWaterSeparator

ServiceInterval:Every40hours

1.Positionthemachineonalevelsurface.

2.DisengagethePTO,movethemotioncontrollevers

totheneutrallockedpositionandsettheparking

brake.

3.Stoptheengine,removethekey,andwaitforall

movingpartstostopbeforeleavingtheoperating

position.

4.Locatethewaterseparatoratthebackleftofthe

machine.

5.Placeadrainpanbelowthewaterseparator.

6.Openthedrainvalveonthewaterseparator

approximatelyoneturntoallowwaterandother

contaminatestodrain(Figure15).

7.Closethedrainvalvewhenonlydieselfuelcomes

out(Figure15).

Figure15

1.Waterseparator

3.Rightsideofmachine

2.Drainvalve

ChangingtheFuelFilter

ServiceInterval:Every400hours/Yearly(whichever

comesrst)(moreoftenindirtyor

dustyconditions).

Neverinstalladirtyfuellterifitisremovedfromthe

fuelline.

1.Allowthemachinetocooldown.

2.DisengagethePTO,movethemotioncontrollevers

totheneutrallockedpositionandsettheparking

brake.

3.Stoptheengine,removethekey,andwaitforall

movingpartstostopbeforeleavingtheoperating

position.

4.Closethefuelshut-offvalve.

5.Loosenthetwohoseclampsanddisconnectthefuel

linesfromthefuellter(Figure16).

6.Installanewlter.Connectthefuellinestothefuel

lterandinstallthetwohoseclamps.

7.Openthefuelshut-offvalve.

8.Starttheengineandcheckforleaks.

Figure16

1.Fuellter3.Rightsideofmachine

2.Hoseclamps

Notes:

Toro Bio-Diesel Kit, 2006 and Before Daihatsu-Powered Z Master Riding Mower Installation guide

Brand: Toro

Model: Bio-Diesel Kit, 2006 and Before Daihatsu-Powered Z Master Riding Mower

Type: Installation guide

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Toro Bio-Diesel Kit, 2006 and Before Daihatsu-Powered Z Master Riding Mower Installation guide

Toro Bio-Diesel Kit, 2006 and Before Daihatsu-Powered Z Master Riding Mower Installation guide

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