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.Areor
explosionfromfuelcanburnyouandothers
andcandamageproperty.
•Wipeupanyfuelthatspills.
•Neverllthefueltankinsideanenclosed
trailer.
•Neversmokewhenhandlingfuel,andstay
awayfromanopenameorwherefuel
fumesmaybeignitedbyaspark.
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescription
Qty.
Use
1
Fuelselectorvalvewithhoses1
Installthenewfuelselectorvalve.
2
Template(locatedinthebackofthese
instructions)
1
Drillholesforthewaterseparatorand
fuelpumpbrackets.
SmallR-clamp
1
Bolt(1/4x1–1/4inches)
1
Locknut(1/4inch)
1
LargeR-clamp1
Bolt(5/16x1-3/4inches)
1
Bolt(5/16x3/4inch)
1
Locknut(5/16inch)
2
3
Waterseparator1
Installthewaterseparatorandfuel
pump.
Hose1
Hoseclamp8
4
Fuelpumpharness1
Connectthefuelhosesandthefuel
pumpharness.
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
fromanopenameorwherefuelfumesmaybe
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
000
0000
0000
0000
0000
Figure2
1.Righthandfueltank
shown
3.Frontfueltankconnection
2.Rearfueltankconnection
11.Followthefuelhosesfromtheexistingselector
valveandremovethehosesfromthefuellterand
thefueltanks.
12.Disconnecttheelectricalconnectionforthefuel
pumpfromthemainwireharness.Rememberthe
locationofthisconnectionbecauseitwillbeused
forthenewfuelpump.
13.Removetheexistingfuelhosefromtheengineand
removetheexistingfuelltersfromthemachine
(Figure3).
Figure3
1.Existingfuellters
2.Fuelhoseconnectedto
engine
14.Removetheexistingfuelselectorvalve.Referto
Figure4.Savetheexistingsoftware.
2
Figure4
1.Hosetoremove
2.Closefuelselectorvalve
15.Usingthepreviouslyremovedhardware,installthe
newfuelselectorvalve(Figure5).
Figure5
1.Newfuelselectorvalve
3.Existingwasher
2.Bracket4.Existingnut
2
DrillingHolesfortheWater
SeparatorandtheFuelPump
Brackets
Partsneededforthisprocedure:
1
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).
3
Figure7
1.Hoodsideplate4.Template
2.Drilla17/64inchholeinto
theexistinghole
5.Drilltwo11/32inchholes
intothehoodsupport
brackethere
3.Enginestrap
6.Installtheengineguardstraptothebackofthe
machine.
7.Installthehoodsupportbracketwiththepreviously
removednutsandbolts.
3
InstallingtheWaterSeparator
andFuelPump
Partsneededforthisprocedure:
1
SmallR-clamp
1
Bolt(1/4x1–1/4inches)
1
Locknut(1/4inch)
1LargeR-clamp
1
Bolt(5/16x1-3/4inches)
1
Bolt(5/16x3/4inch)
2
Locknut(5/16inch)
1Waterseparator
Procedure
1.Routethefuellterandfuelpumptowardsthe
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).
4
Figure9
1.LargeR-clampwithwater
separator
3.Bolt(5/16x1-3/4inches)
2.Locknut(1/4inch)4.Bolt(5/16x3/4inch)
4
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
3
2
1
5
6
5
4
7
Figure10
1.Fuelpump5.Hoseclamp
2.Fuellter
6.Waterseparator
3.Valveselector7.Fuelpumpharness
4.Hose
5.Installthefabricsleeveontherighthandtankhoses.
SeeFigure11forthecorrecthoses.
6.Installthehoseswiththefabricsleeveintothetwo
R-clamps(Figure11).
7.Installthelongerhosetothefrontrighthandfuel
tankconnection(Figure11).
8.Installtheshorthosetothebackrighthandfueltank
connection(Figure11).
5
000
000
0000
0000
0000
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
5
InstallingtheDecalsandFuel
Caps
Partsneededforthisprocedure:
2
Lowsulfurdecal
2Fuelcap
1Dieseldecal
Procedure
1.Lowertheenginehood.
2.Removetheexistingdecaloneachside.
3.Installalowsulfurdecaloneachsideoftheengine
hood.SeeFigure13forthecorrectposition.
G008099
1
2
Figure13
1.Enginehood
2.Lowsulfurdecal
4.Cleantheexistingfrontdecalandtheareaaroundit
andletitdry(Figure14).
5.Installthenewdieseldecalovertheexistingone.
SeeFigure14.
6
G008999
1
Figure14
1.Dieseldecal
6.Removebothexistingfuelcapsandreplacethem
withthenewfuelcaps(Figure15).
G008998
1
Figure15
1.Newfuelcap
6
VerifyingtheConnections
NoPartsRequired
Procedure
1.Openthefuelselectorvalve.
2.Openthewaterseparatordrainvalveuntilfuelstarts
todrainoutandclosethevalve(Figure16).
3.Ensuretherearenoleaksatthefuelhose
connections.
4.Installthenegativebatteryontothebattery.
5.Starttheengineandensuretherearenoleaks.
Figure16
1.Drainvalve
3.Backofmachine
2.Waterseparator
7
Operation
AddingFuel
Afterthiskitisinstalled,thismachinecanusea
biodieselblendedfuelofuptoB20(20%biodiesel,
80%petrodiesel).Thepetrodieselportionshouldbe
loworultralowsulfur.
Observethefollowingprecautions:
•Thebiodieselportionofthefuelmeetspecication
ASTMD6751orEN14214.
•TheblendedfuelcompositionshouldmeetASTM
D975orEN590.
•Paintedsurfacesmaybedamagedbybiodiesel
blends.
•UseB5(biodieselcontendof5%)orlesserblend
incoldweather.
•Monitorseals,hoses,gasketsincontactwithfuelas
theymaybedegradeovertime.
•Fuellterpluggingmaybeexpectedforatimeafter
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
lowerashpointandpourpointcharacteristics,
thereforeeasingstartabilityandlesseningchances
ofchemicalseparationofthefuelduetolower
temperatures(waxappearance,whichmaypluglters).
Useofsummergradedieselfuelabove20°F(-7°C)will
contributetowardlongerlifeofthepumpcomponents.
Important:Donotusekeroseneorgasoline
insteadofdieselfuel.Failuretoobservethis
cautionwilldamagetheengine.
Incertainconditions,fuelisextremely
ammableandhighlyexplosive.Areor
explosionfromfuelcanburnyouandothers
andcandamageproperty.
•Fillthefueltankoutdoors,inanopenarea,
whentheengineiscold.Wipeupanyfuel
thatspills.
•Neverllthefueltankinsideanenclosed
trailer.
•Donotllthefueltankcompletelyfull.Add
fueltothefueltankuntilthelevelis1/4to
1/2inch(6to13mm)belowthebottomof
thellerneck.Thisemptyspaceinthetank
allowsfueltoexpand.
•Neversmokewhenhandlingfuel,andstay
awayfromanopenameorwherefuel
fumesmaybeignitedbyaspark.
•Storefuelinanapprovedcontainerandkeep
itoutofthereachofchildren.Neverbuy
morethana30-daysupplyoffuel.
•Alwaysplacefuelcontainersontheground
awayfromyourvehiclebeforelling.
•Donotllfuelcontainersinsideavehicle
oronatruckortrailerbedbecauseinterior
carpetsorplastictruckbedlinersmay
insulatethecontainerandslowthelossof
anystaticcharge.
•Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelsonthe
ground.
•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfromafuel
dispensernozzle.
•Ifafueldispensernozzlemustbeused,keep
thenozzleincontactwiththerimofthefuel
tankorcontaineropeningatalltimesuntil
fuelingiscomplete.
8
Fuelisharmfulorfatalifswallowed.Long-term
exposuretovaporscancauseseriousinjuryand
illness.
•Avoidprolongedbreathingofvapors.
•Keepfaceawayfromnozzleandgastankor
conditioneropening.
•Keepgasawayfromeyesandskin.
FillingtheFuelTank
1.Shuttheengineoffandsettheparkingbrake.
2.Cleanaroundeachfueltankcapandremovethe
cap.Addfueltobothfueltanks,untilthelevelis
1/4to1/2inch(6to13mm)belowthebottomof
thellerneck.Thisspaceinthetankallowsthefuel
toexpand.Donotllthefueltankscompletelyfull.
3.Installfueltankcapssecurely.Wipeupanyfuelthat
mayhavespilled.
4.Ifpossible,llthefueltankaftereachuse.Thiswill
minimizepossiblebuildupofcondensationinside
thefueltank.
9
Maintenance
ServicingtheFuelFilterand
WaterSeparator
ServiceInterval:Every40hours—Drainthewater
separator.
Every400hours/Yearly(whichever
comesrst)—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
Neverinstalladirtyfuellterifitisremovedfromthe
fuelline.
1.Allowthemachinetocooldown.
2.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.
3.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.
4.Closethefuelshut-offvalve(Figure18).
5.Loosenthetwohoseclampsanddisconnectthefuel
linesfromthefuellter(Figure18).
6.Installanewlter.Connectthefuellinestothefuel
lterandinstallthetwohoseclamps(Figure18).
7.Openthefuelshut-offvalve.
8.Starttheengineandcheckforleaks.
Figure18
1.Fuellter4.Leftsideofmachine
2.Hoseclamp
5.Fuelshut-offvalve
3.Fuelpump
10
11
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