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

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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
1
Fuelselectorvalvewithhoses1
Installthenewfuelselectorvalve.
2
Nopartsrequired
–
Removetheexistingwaterseparator
Mountingplate1
Locknut(1/4inch)
1
Fuellterclamp
1
Bolt(5/16x1-3/4inches)
1
Bolt(5/16x3/4inch)
1
Locknut(5/16inch)
2
3
Waterseparator1
Installthenewwaterseparator.
Hose1
Hoseclamp8
J-clamp1
4
Plastictie6
Installingandconnectingthefuelhoses.
Lowsulfurdecal
2
Fuelcap2
5
Dieseldecal1
Installthedecalsandfuelcaps.
6
Nopartsrequired
–
Verifytheconnections.
©2008—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.
OriginalInstructions(EN)
PrintedintheUSA.
AllRightsReserved
1
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).
2
Figure3
1.Existingnut
3.Newfuelselectorvalve
2.Existingwasher
2
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
3
3
InstallingtheNewWater
Separator
Partsneededforthisprocedure:
1Mountingplate
1
Locknut(1/4inch)
1
Fuellterclamp
1
Bolt(5/16x1-3/4inches)
1
Bolt(5/16x3/4inch)
2
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)
4
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).
4
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.
5
9.Installtheshorthosetothebacklefthandfueltank
connection(Figure10).
Figure10
1.Lefthandfueltank4.Shorthose
2.Rearfueltankconnection
5.Longhose
3.Hoseclamp
6.Frontfueltankconnection
10.Installtheplastictiestosecurethehosesfrom
touchinganyhotpartsofthemachineorrubbing
againstthemachine.
5
InstallingtheDecalsandFuel
Caps
Partsneededforthisprocedure:
2
Lowsulfurdecal
2Fuelcap
1Dieseldecal
Procedure
1.Lowertheenginehood.
2.Removetheexistingdecaloneachside.
3.Installalowsulfurdecaloneachsideoftheengine
hood.SeeFigure4forthecorrectposition.
G008099
1
2
Figure11
1.Enginehood
2.Lowsulfurdecal
4.Cleantheexistingfrontdecalandtheareaaroundit
andletitdry(Figure12).
5.Installthenewdieseldecalovertheexistingone.
SeeFigure12.
G008999
1
Figure12
1.Dieseldecal
6.Removebothexistingfuelcapsandreplacethem
withthenewfuelcaps(Figure13).
G008998
1
Figure13
1.Newfuelcap
6
6
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.
7
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.
8
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
9
Notes:
10
Notes:
11
/