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  3. Dual Fuel Pump Kit, Z500 Z Master Riding Mower
Dual Fuel Pump Kit, Z500 Z Master Riding Mower

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

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  • What is the purpose of the fuel selector valve and switch?
    How do I operate the fuel selector valve and switch?
    Why is it important to set the fuel selector valve and switch to the same tank?
    What is the procedure for preparing the mower for installation?
    What hoses need to be removed from the right-hand fuel tank?
    Which fuel hoses need to be disconnected from the engine?
    How do I install the new fuel pumps?
    How do I connect the new fuel hoses?
FormNo.3362-988RevA
DuelFuelPumpKit
forDFIZMaster
®
Mowers
ModelNo.115–7490
InstallationInstructions
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescription
Qty.
Use
1
Nopartsrequired
–
Preparethemower.
Fuelselectorvalvewithhosesandwire
harness
1
Hoseclamp2
Fuelselectorbracket1
2
Switch
1
Changingthefuelhoses.
Fuelpump1
Carriagebolt(1/4x3/4inch)
2
Carriagebolt(1/4x5/8inch)
2
Washer(1/4inch)
4
Nut(1/4inch)
4
Plastictie4
Coverplate
1
Fuelpumpbracket1
Lefthandfuelpumpbracket
1
Bolt(3/8x2-1/4inch)
2
Curvedwasher
2
Spacer
2
Bolt(3/8x7/8inch)
2
Flatwasher(3/8inch)
2
Shortfuelhose(3inch(7.6cm))
2
Longfuelhose
1
3
Hoseclamp10
Installthefuelpumps.
1
PreparingtheMower
NoPartsRequired
Procedure
1.Thoroughlycleanmower.Alldebrismustbe
removedtoensurethekitwilltproperly.
2.Repairallbentordamagedareasandreplaceany
missingparts.
3.Drainthefuelfrombothfueltanks.
©2009—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.
OriginalInstructions(EN)
PrintedintheUSA.
AllRightsReserved
2
ChangingtheFuelHoses
Partsneededforthisprocedure:
1Fuelselectorvalvewithhosesandwireharness
2Hoseclamp
1Fuelselectorbracket
1
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).
2
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).
3
Figure7
1.Existingbolt
4.Newfuelselectorvalve
2.Existingnut
5.Upperrighthandfueltank
connection
3.Routethehoses
3
InstallingtheFuelPumpsand
WireHarness
Partsneededforthisprocedure:
1Fuelpump
2
Carriagebolt(1/4x3/4inch)
2
Carriagebolt(1/4x5/8inch)
4
Washer(1/4inch)
4
Nut(1/4inch)
4Plastictie
1
Coverplate
1Fuelpumpbracket
1
Lefthandfuelpumpbracket
2
Bolt(3/8x2-1/4inch)
2
Curvedwasher
2
Spacer
2
Bolt(3/8x7/8inch)
2
Flatwasher(3/8inch)
2
Shortfuelhose(3inch(7.6cm))
1
Longfuelhose
10Hoseclamp
Procedure
1.Assemblethenewfuelpumptothecoverplateand
righthandfuelpumpbracketwith2carriagebolts
(1/4x3/4inches),2washers(1/4inch)and2lock
nuts(1/4inch)(Figure8).
Note:Thefuelpumpmustbeassembledasshown
inFigure8withthewiresontherightside.
4
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
5
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).
6
Figure13
1.Brakecrossshaft
2.Plasticties
24.Filleachtankwithagallonoffuel.
25.Beforeoperatingthemachinecheckforleaksatall
hoseconnections.Ensurenofuelleaksoccurwhen
themachineisrstrun.
7
Operation
UsingtheFuelSelectorValve
andSwitch
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
Theelectricalswitchmustbesettothesamefueltank
asthemechanicalfuelselectorvalve.
Figure14
1.Switch2.Mechanicalfuelselectorvalve
8
/