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

Brand: Toro

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

Category: Car kits

Type: Installation guide

Toro Bio-Diesel Kit, 2006 and Before Kubota-Powered Z Master Riding Mower allows you to use a biodiesel blended fuel of up to B20 (20% biodiesel, 80% petrodiesel). The petrodiesel portion should be low or ultra low sulfur. You can install this kit on machines with a serial number of 269999999 and below. After you install this kit, verify the connections by opening the fuel selector valve and the water separator drain valve and ensuring there are no leaks at the fuel hose connections.

FormNo.3360-696RevA

Bio-DieselKit

2006andBeforeKubota

-PoweredZMaster

RidingMowers

ModelNo.115–3564

InstallationInstructions

Thiskitisformachineswithaserialnumberof

269999999andBelow.

Afterthiskitisinstalled,thismachinecanusea

biodieselblendedfuelofuptoB20(20%biodiesel,80%

petrodiesel).Thepetrodieselportionshouldbelowor

ultralowsulfur.RefertotheOperationSectionforfuel

precautions.

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.

Template(locatedinthebackofthese

instructions)

Drillholesforthewaterseparatorand

fuelpumpbrackets.

SmallR-clamp

Bolt(1/4x1–1/4inches)

Locknut(1/4inch)

LargeR-clamp1

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

Bolt(5/16x3/4inch)

Locknut(5/16inch)

Waterseparator1

Installthewaterseparatorandfuel

pump.

Hose1

Hoseclamp8

Fuelpumpharness1

Connectthefuelhosesandthefuel

pumpharness.

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.Knob2.Frontenginepanel

8.Todrainthefueltank,placeacleancontainerunder

thefrontfueltankconnection,removethefuelhose

fromtheconnectionorcutthefuellineanddirect

thefuellineintothecontainer(Figure2).

9.Allowthefueltodrainintothecontainerandwipe

upanyspilledfuel.Ensurethefuellineisremoved

fromthetankconnection(Figure2).

10.Drainthefuelfromtheoppositetank.

000

0000

Figure2

1.Righthandfueltank

shown

3.Frontfueltankconnection

2.Rearfueltankconnection

11.Followthefuelhosesfromtheexistingselector

valveandremovethehosesfromthefuellterand

thefueltanks.

12.Disconnecttheelectricalconnectionforthefuel

pumpfromthemainwireharness.Rememberthe

locationofthisconnectionbecauseitwillbeused

forthenewfuelpump.

13.Removetheexistingfuelhosefromtheengineand

removetheexistingfuelltersfromthemachine

(Figure3).

Figure3

1.Existingfuellters

2.Fuelhoseconnectedto

engine

14.Removetheexistingfuelselectorvalve.Referto

Figure4.Savetheexistingsoftware.

Figure4

1.Hosetoremove

2.Closefuelselectorvalve

15.Usingthepreviouslyremovedhardware,installthe

newfuelselectorvalve(Figure5).

Figure5

1.Newfuelselectorvalve

3.Existingwasher

2.Bracket4.Existingnut

DrillingHolesfortheWater

SeparatorandtheFuelPump

Brackets

Partsneededforthisprocedure:

Template(locatedinthebackoftheseinstructions)

Procedure

1.Raisethehoodontheengine.

2.Removethenutsandboltsholdingthehoodsupport

bracket.Savethenutsandbolts(Figure6).

3.Removetheboltforthetopengineguardstrapfrom

themachine(Figure6).

Figure6

1.Removethesenutsand

boltsfromthehood

supportbracket

3.Hoodsideplate

2.Removethisboltfromthe

topengineguardstrap

4.Usingthepapertemplateinthebackofthese

instructions,markanddrill2holes(11/32inch

diameter)intothehoodsupportbracket(Figure7).

5.Drilla17/64inchdiameterholeintotheexisting

holeintheengineguardstrap(Figure7).

Figure7

1.Hoodsideplate4.Template

2.Drilla17/64inchholeinto

theexistinghole

5.Drilltwo11/32inchholes

intothehoodsupport

brackethere

3.Enginestrap

6.Installtheengineguardstraptothebackofthe

machine.

7.Installthehoodsupportbracketwiththepreviously

removednutsandbolts.

InstallingtheWaterSeparator

andFuelPump

Partsneededforthisprocedure:

SmallR-clamp

Bolt(1/4x1–1/4inches)

Locknut(1/4inch)

1LargeR-clamp

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

Bolt(5/16x3/4inch)

Locknut(5/16inch)

1Waterseparator

Procedure

1.Routethefuellterandfuelpumptowardsthe

backoftheengine.Makesurenopartsorhosesare

touchingthemachineinareasthatwillgethot.

2.InstallthesmallR-clamparoundthefuelpumpand

installittotheenginestrapwithabolt(1/4x1–1/4

inches)andnut(1/4inch)(Figure8).

Figure8

1.SmallR-clampwithfuel

pumpinstalled

3.Bolt(1/4x1–1/4inches)

2.Locknut(1/4inch)

3.InstallthewaterseparatorintothelargeR-clamp

andinstallittothehoodsupportbracketwithabolt

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

2locknuts(5/16inch)(Figure9).

Figure9

1.LargeR-clampwithwater

separator

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

2.Locknut(1/4inch)4.Bolt(5/16x3/4inch)

ConnectingtheFuelHoses

andtheFuelPumpHarness

Partsneededforthisprocedure:

1Hose

8Hoseclamp

1Fuelpumpharness

Procedure

1.Installthehoseinstalledonthefuelpumptothe

waterseparatorwithahoseclamp.SeeFigure10

forthecorrectconnectiontouseonthetopofthe

waterseparator.

2.Installthehosetothewaterseparatorandtothe

enginefuelintakewith2hoseclamps(Figure10).

3.Installtheelectricalfuelpumpwiretothefuelpump

harness.

4.Installthefuelpumpharnesstothemainwire

harness(Figure10).

G008098

Figure10

1.Fuelpump5.Hoseclamp

2.Fuellter

6.Waterseparator

3.Valveselector7.Fuelpumpharness

4.Hose

5.Installthefabricsleeveontherighthandtankhoses.

SeeFigure11forthecorrecthoses.

6.Installthehoseswiththefabricsleeveintothetwo

R-clamps(Figure11).

7.Installthelongerhosetothefrontrighthandfuel

tankconnection(Figure11).

8.Installtheshorthosetothebackrighthandfueltank

connection(Figure11).

000

0000

Figure11

1.Righthandfueltank

4.Fuelselectorvalve

2.R-clamp5.Hoseclamp

3.Fabricsleeve6.Fueltankconnection

9.Installthelongerfuelhosetothefrontlefthand

fueltankconnection.SeeFigure12.forthecorrect

hoses.

10.Installtheshorthosetothebacklefthandfueltank

connection(Figure12).

Figure12

1.Fuelselectorvalve

4.Longfuelhose

2.Hoseclamp

5.Shortfuelhose

3.Fueltankconnection

InstallingtheDecalsandFuel

Caps

Partsneededforthisprocedure:

Lowsulfurdecal

2Fuelcap

1Dieseldecal

Procedure

1.Lowertheenginehood.

2.Removetheexistingdecaloneachside.

3.Installalowsulfurdecaloneachsideoftheengine

hood.SeeFigure13forthecorrectposition.

G008099

Figure13

1.Enginehood

2.Lowsulfurdecal

4.Cleantheexistingfrontdecalandtheareaaroundit

andletitdry(Figure14).

5.Installthenewdieseldecalovertheexistingone.

SeeFigure14.

G008999

Figure14

1.Dieseldecal

6.Removebothexistingfuelcapsandreplacethem

withthenewfuelcaps(Figure15).

G008998

Figure15

1.Newfuelcap

VerifyingtheConnections

NoPartsRequired

Procedure

1.Openthefuelselectorvalve.

2.Openthewaterseparatordrainvalveuntilfuelstarts

todrainoutandclosethevalve(Figure16).

3.Ensuretherearenoleaksatthefuelhose

connections.

4.Installthenegativebatteryontothebattery.

5.Starttheengineandensuretherearenoleaks.

Figure16

1.Drainvalve

3.Backofmachine

2.Waterseparator

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

ServicingtheFuelFilterand

WaterSeparator

ServiceInterval:Every40hours—Drainthewater

separator.

Every400hours/Yearly(whichever

comesrst)—Replacethefuel

lter(moreoftenindirtyordusty

conditions).

DrainingtheWaterSeparator

1.Positionthemachineonalevelsurface.

2.DisengagethePTO,movethemotioncontrollevers

totheneutrallockedpositionandsettheparking

brake.

3.Stoptheengine,removethekey,andwaitforall

movingpartstostopbeforeleavingtheoperating

position.

4.Locatethewaterseparatoratthebackleftofthe

machine.

5.Placeadrainpanbelowthewaterseparator.

6.Openthedrainvalveonthewaterseparator

approximatelyoneturntoallowwaterandother

contaminatestodrain(Figure17).

7.Closethedrainvalvewhenonlydieselfuelcomes

out(Figure17).

Figure17

1.Drainvalve

3.Backofmachine

2.Waterseparator

ChangingtheFuelFilter

Neverinstalladirtyfuellterifitisremovedfromthe

fuelline.

1.Allowthemachinetocooldown.

2.DisengagethePTO,movethemotioncontrollevers

totheneutrallockedpositionandsettheparking

brake.

3.Stoptheengine,removethekey,andwaitforall

movingpartstostopbeforeleavingtheoperating

position.

4.Closethefuelshut-offvalve(Figure18).

5.Loosenthetwohoseclampsanddisconnectthefuel

linesfromthefuellter(Figure18).

6.Installanewlter.Connectthefuellinestothefuel

lterandinstallthetwohoseclamps(Figure18).

7.Openthefuelshut-offvalve.

8.Starttheengineandcheckforleaks.

Figure18

1.Fuellter4.Leftsideofmachine

2.Hoseclamp

5.Fuelshut-offvalve

3.Fuelpump

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

Brand: Toro

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

Category: Car kits

Type: Installation guide

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

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

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