Toro Dual Fuel Pump Kit, Z500 Z Master Riding Mower Installation guide

Brand: Toro

Model: Dual Fuel Pump Kit, Z500 Z Master Riding Mower

Type: Installation guide

Toro Dual Fuel Pump Kit, Z500 Z Master Riding Mower enables dual-fuel capability by allowing you to switch between gasoline and propane fuel sources. This kit includes all necessary components for installation, such as the fuel selector valve, hoses, wire harness, fuel pumps, and mounting hardware. The fuel selector valve and switch let you easily select the desired fuel tank. Detailed instructions with illustrations guide you through the installation process, making it suitable for DIY enthusiasts.

FormNo.3362-988RevA

DuelFuelPumpKit

forDFIZMaster

Mowers

ModelNo.115–7490

InstallationInstructions

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

Installation

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

Qty.

Use

Nopartsrequired

–

Preparethemower.

Fuelselectorvalvewithhosesandwire

harness

Hoseclamp2

Fuelselectorbracket1

Switch

Changingthefuelhoses.

Fuelpump1

Carriagebolt(1/4x3/4inch)

Carriagebolt(1/4x5/8inch)

Washer(1/4inch)

Nut(1/4inch)

Plastictie4

Coverplate

Fuelpumpbracket1

Lefthandfuelpumpbracket

Bolt(3/8x2-1/4inch)

Curvedwasher

Spacer

Bolt(3/8x7/8inch)

Flatwasher(3/8inch)

Shortfuelhose(3inch(7.6cm))

Longfuelhose

Hoseclamp10

Installthefuelpumps.

PreparingtheMower

NoPartsRequired

Procedure

1.Thoroughlycleanmower.Alldebrismustbe

removedtoensurethekitwilltproperly.

2.Repairallbentordamagedareasandreplaceany

missingparts.

3.Drainthefuelfrombothfueltanks.

8111LyndaleAvenueSouth

Bloomington,MN55420

Registeratwww.Toro.com.

OriginalInstructions(EN)

PrintedintheUSA.

AllRightsReserved

ChangingtheFuelHoses

Partsneededforthisprocedure:

1Fuelselectorvalvewithhosesandwireharness

2Hoseclamp

1Fuelselectorbracket

Switch

Procedure

1.Loosenboththelefthandandrighthandlowerfuel

tankttingsandrotatethemforward.Keepthem

looseforeaseofassembly.

2.Removebothfuelhosesontherighthandfueltank

(Figure1).

Figure1

Righthandtankshown

1.Righthandfueltank3.Lowerfueltankconnection

2.Upperfueltankconnection

3.Removethelowerfuelhoseonthelefthandfuel

tank.DoNOTremovethetopfuelhoseontheleft

handfueltank(Figure2).

Figure2

Lefthandtankshown

1.Lefthandfueltank

3.Removehosehere

2.Upperfueltankconnection

(Donotremovehosehere)

4.Disconnectthereturnhosefromtheengineatthe

fuelselectorvalve.Thisislocatedatthecentertop

port(Figure3).

5.Disconnectthelefthandtopfuelhoseatthefuel

selectorvalve.Thisislocatedatthelefthandtop

port(Figure3).

Figure3

1.Returnhosefromthe

engine

3.Lefthandtopfuelhose

2.Centertopport4.Lefthandtopport

6.Removetheexistingfuelselectorvalveandthefuel

selectorvalvebracket.Savethenutandbolt.

7.Removethefuelhosefromthefuelselectorvalveto

fuellter(Figure4).

8.Removethefuelhosefromthefuelltertothefuel

pump(Figure4).

9.Removethefuelhosefromthefuelpumptothe

engine(Figure4).

10.Disconnectthefuelpumpfromthewireharness.

Rememberthisconnectionbecausethenewwire

harnesswillconnecthere(Figure4).

11.Removefuelpumpandsetasideforinstallationlater

(Figure4).

Figure4

1.Selectorvalve

5.Fuelpump

2.Hosefromthefuelselector

valvetofuellter

6.Hosefromthefuellterto

fuelpump

3.Wireharnessconnection

7.Fuellter

4.Hosefromthefuelpump

totheengine

12.Installthefuelhosefromthetoplefthandfueltank

tothenewselectorvalveatthelefthandtopport

withanewhoseclamp.Ensuretheclampistight

(Figure5).

13.Installthereturnfuelhosefromtheenginetothe

newselectorvalveatthecentertopportwithanew

hoseclamp.Ensuretheclampistight(Figure5).

Figure5

1.Returnhosefromthe

engine

3.Lefthandtopfuelhose

2.Centertopport4.Lefthandtopport

14.RoutethefuellinesasshowninFigure7.

15.Locatethelongerofthetwonewrighthandfuel

hosesattachedtothefuelselectorvalveassembly

andconnectittotheupperrighthandtanktting

(Figure7).

16.Installtheswitchintothebracketensuringthe

locatingpinonthebottomoftheswitchisonthe

leftsideoftheunit(Figure6).

Figure6

1.Righthandside

3.Lefthandside

2.Locatingpin

17.Installthenewfuelselectorvalvetothenewbracket

andconnectthewireharnesstotheswitch.

18.Installthenewbrackettothemachineusingthe

existingboltandnut(Figure7).

Figure7

1.Existingbolt

4.Newfuelselectorvalve

2.Existingnut

5.Upperrighthandfueltank

connection

3.Routethehoses

InstallingtheFuelPumpsand

WireHarness

Partsneededforthisprocedure:

1Fuelpump

Carriagebolt(1/4x3/4inch)

Carriagebolt(1/4x5/8inch)

Washer(1/4inch)

Nut(1/4inch)

4Plastictie

Coverplate

1Fuelpumpbracket

Lefthandfuelpumpbracket

Bolt(3/8x2-1/4inch)

Curvedwasher

Spacer

Bolt(3/8x7/8inch)

Flatwasher(3/8inch)

Shortfuelhose(3inch(7.6cm))

Longfuelhose

10Hoseclamp

Procedure

1.Assemblethenewfuelpumptothecoverplateand

righthandfuelpumpbracketwith2carriagebolts

(1/4x3/4inches),2washers(1/4inch)and2lock

nuts(1/4inch)(Figure8).

Note:Thefuelpumpmustbeassembledasshown

inFigure8withthewiresontherightside.

Figure8

1.Righthandfuelpump

bracket

6.Locknut(1/4inch)

2.Carriagebolt(1/4x3/4

inch)

7.Fuelhose(3inch(7.6cm))

3.Coverplate

8.Hoseclamp

4.Newfuelpump9.Wirescomingoutoffuel

pump

5.Washer(1/4inch)

2.Installashortfuelhosetothefuelpumpwithahose

clamponthesidethatthewiresdonotcomeout

ofthepump.

Note:Ensurethesmallfuelhoseisinstalledonthe

endofthefuelpumpthatdoesNOThavewires

comingoutofit.

3.Raiseuptherighthandsideofthemachineand

loweritontoajackstand.Removerighthandtire.

4.Removeboltsandnutsholdingtherighthandbrake

crossshaftbearingtotheframe.

Note:Temporarilyreleasethebrakestoeasethe

removaloftheboltsandnutsholdingthecrossshaft.

5.Connectthenewfuelhosefromthefuelselector

valvetothewiresideofthefuelpumpwithahose

clampandtightentheclamp.

6.Installnewfuelpumpandbracketassemblyusing

thenutspreviouslyremovedandnewbolts(3/8x

7/8inch)andatwashers(3/8inch)(Figure9).

Don’ttightenthefasteners.

Beforetighteningthefasteners,connecttheshort

fuelhoseonthefuelpumpandtothettingon

thebottomofthefueltankwithahoseclampand

tightentheclamp.Ensurethefuellineisnotkinked

onceeverythingistightened.

Figure9

1.Existingnut

4.Shortfuelhoseinstalled

2.Rightsideofmachine5.Washer(3/8inch)

3.Newfuelpumpassembly6.Bolt(3/8x7/8inches)

7.Engagetheparkingbrake.

8.Onthelefthandsideofthemachine,removethe

upperfronttwofrontcarrierframebolts.

9.Installlefthandpumpbracketwith2spacers

betweenthecarrierframeandbracketusingthe

nutspreviouslyremovedand2newbolts(3/8x

2-1/4inches)and2newcurvedwashers(3/8inch)

(Figure10).

Figure10

1.Lefthandpumpbracket4.Spacer

2.Frontofmachine5.Washer(3/8inch)

3.Nut(3/8inch)6.Bolt(3/8x2-1/4inches)

10.Installashortfuelhosetofuelpumpremovedearlier

withahoseclampandtightentheclamp(Figure11).

Note:Installthesmallfuelhoseontheendofthe

fuelpumpthatdoesNOThavewirescomingout

ofit.

11.Routethenewfuelhosefromthefuelselectorvalve

throughtheframeandbracketasshowninFigure12

andFigure13andconnectittothewiresideofthe

fuelpumpwithahoseclamp.Tightentheclamp.

12.Positionthefuelpumpintoplaceandconnectthe

shortfuelhose(3inch(7.6cm))tothettingonthe

bottomoftheleftfueltankwithahoseclampand

tightentheclamp.Ensurethefuellineisnotkinked

onceeverythingistightened(Figure11).

13.Assemblethefuelpumptothelefthandfuelpump

bracketwith2carriagebolts(1/4x5/8inch),2nuts

(1/4inch),and2washers(1/4inch)(Figure11).

14.Installfuellterremovedpreviouslytothe3inch

hoseattachedtothebottomcenterportofthe

selectorvalvewithahoseclamp.

Note:Thefuelltermustbeinstalledasshown,

withlargerpartoftheltertowardtherearofthe

unit.

Figure11

1.Leftthandfuelpump

bracket

5.Fuelhose(3inch(7.6cm))

2.Washer(1/4inch)6.Existingfuelpump

3.Locknut(1/4inch)7.Carriagebolt(1/4x5/8

inch)

4.Hoseclamp

15.Connectthenewlongfuelhosetothelterandthe

engineusing2newhoseclamps.Ensurethehoseis

routedthesameastheonepreviouslyremoved.

16.Checkandtightenallboltsandallfuelhoseclamps.

17.Tightenbothlowerfueltankttings.

18.Installtherighthandtire.Removethejackstand.

19.Routethenewwireharnesstothelefthandfuel

pumpthroughtheframefollowingthepathofthe

fuellineandconnectittothefuelpump.Keep

thefuelpumpwiresinsidethelefthandfuelpump

bracket.Pullthemtowardstherearandconnectthe

newwireharness(Figure12).

20.Connectnewwireharnesstotherighthandfuel

pumpandfoldanyextrawireanduseaplastictieto

securethefoldedwire(Figure12).

21.Plugthenewwireharnesstomainwireharnesson

unit.Thisisthesameconnectionthatwasusedfor

theexistingfuelpump(Figure12).

Figure12

1.Newharness

3.Switch

2.Existingmachineharness

22.Looselyinstallthefuelhoseassemblytothebrake

crossshaftasshownwith2plasticties(Figure13).

23.Useaplastictietosecurethefuelhosethrough

thecenterholesinthelefthandfuelpumpbracket

(Figure13).

Figure13

1.Brakecrossshaft

2.Plasticties

24.Filleachtankwithagallonoffuel.

25.Beforeoperatingthemachinecheckforleaksatall

hoseconnections.Ensurenofuelleaksoccurwhen

themachineisrstrun.

Operation

UsingtheFuelSelectorValve

andSwitch

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

Theelectricalswitchmustbesettothesamefueltank

asthemechanicalfuelselectorvalve.

Figure14

1.Switch2.Mechanicalfuelselectorvalve

Toro Dual Fuel Pump Kit, Z500 Z Master Riding Mower Installation guide

Toro Dual Fuel Pump Kit, Z500 Z Master Riding Mower Installation guide

Toro Dual Fuel Pump Kit, Z500 Z Master Riding Mower Installation guide

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