Toro 115-3563 Installation Instructions

Bio-DieselFuelKit

2006andBeforeDaihatsu-PoweredZMasterRidingMowers

ModelNo.115–3563

Afterthiskitisinstalled,thismachinecanusea
biodieselblendedfuelofuptoB20(20%biodiesel,80%
petrodiesel).Thepetrodieselportionshouldbelowor
ultralowsulfur.

FormNo.3360-694RevA

InstallationInstructions

Incertainconditions,fuelisextremely
ammableandhighlyexplosive.Areor
explosionfromfuelcanburnyouandothers
andcandamageproperty.

Fuelisharmfulorfatalifswallowed.Long-term
exposuretovaporscancauseseriousinjuryand
illness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor
conditioneropening.

•Keepfuelawayfromeyesandskin.

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1
2

3

4

5

Fuelselectorvalvewithhoses1

Nopartsrequired

Mountingplate1
Locknut(1/4inch)
Fuellterclamp
Bolt(5/16x1-3/4inches)
Bolt(5/16x3/4inch)
Locknut(5/16inch)
Waterseparator1
Hose1
Hoseclamp8
J-clamp1
Plastictie6
Lowsulfurdecal
Fuelcap2
Dieseldecal1

•Wipeupanyfuelthatspills.

•Neverllthefueltankinsideanenclosed
trailer.

•Neversmokewhenhandlingfuel,andstay
awayfromanopenameorwherefuel
fumesmaybeignitedbyaspark.

Qty.

Installthenewfuelselectorvalve.

–

1
1
1
1
2

2

Removetheexistingwaterseparator

Installthenewwaterseparator.

Installingandconnectingthefuelhoses.

Installthedecalsandfuelcaps.

Use

6

©2008—TheToro®Company
8111LyndaleA venueSouth
Bloomington,MN55420

Nopartsrequired

Registeratwww.Toro.com.

–

Verifytheconnections.

OriginalInstructions(EN)

PrintedintheUSA.

AllRightsReserved

1

InstallingtheNewFuel
SelectorValve

Partsneededforthisprocedure:

1Fuelselectorvalvewithhoses

Procedure

10.Drainthefuelfromtheoppositetank.

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).

Figure2

1.Righthandfueltank
shown

2.Rearfueltankconnection

11.Followthefuelhosesfromtheexistingselector
valveandremovethehosefromthefuellterand
thefueltanks.

12.Removetheexistingfuelhosefromtheengineand
removetheexistingfuellterfromthemachine.

13.Removetheexistingfuelselectorvalve.Referto
Figure3.Savetheexistinghardware.

14.Usingthepreviouslyremovedhardware,installthe
newfuelselectorvalve(Figure3).

3.Frontfueltankconnection

Figure1

1.Frontenginepanel2.Knob

8.Todrainthefueltank,placeacleancontainerunder
thefrontfueltankconnection,removethefuelhose
fromthefrontconnectionorcutthefuellineand
directthefuellineintothecontainer(Figure2).

9.Allowthefueltodrainintothecontainerandwipe
upanyspilledfuel.Ensurethefuellineisremoved
fromthetankconnection(Figure2).

2

Figure3

1.Existingnut

2.Existingwasher

3.Newfuelselectorvalve

2

RemovingtheExistingWater
Separator

Figure4

1.Frontenginepanel2.Knob

3.Locatethehosebetweenthewaterseparatorandthe
fuelselectorvalve.Removethefuelhosefromthe
fuelselectorvalve(Figure5).

4.Locatethehosebetweenthewaterseparatorandthe
fuelselectorvalve.Removethefuelhosefromthe
theengine(Figure5).Rememberthelocationwhere
thefuelhosewasconnectedtotheengine.

5.Removetheexistingwaterseparatorfromthe
machine.

NoPartsRequired

Procedure

Important:Allowtheenginetocoolbefore

installingthiskit.

1.Tilttheseatforwardandremovethefrontengine
panel(Figure4).

2.Closethefuelselectorvalve.

1.Fuelhosefromthe
separatortotheengine
(makenotewherethe
connectionisonthe
engine)

2.Hosefromfuelselector
valve

Figure5

3.Existingwaterseparator

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).

Figure6

1.Locknut(5/16inch)7.Bolt(5/16x1-3/4inches)

2.J-clamp8.Mountingplate

3.Existinglocknut

4.Existingwasher10.Waterseparator

5.Existingbolt11.Enginestrap

6.Bolt(5/16x3/4inch)

9.Fuellterbracket

3.Installthewaterseparatorintothefuellterclamp
andinstallittothemountingbracketwithabolt
(5/16x1-3/4inches),abolt(5/16x3/4inch),and
2locknuts(5/16inch)(Figure6).

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

5.Installthenewfuelhosetothewaterseparatorand
totheenginefuelconnectionwith2hoseclamps
(Figure8).Theconnectiontotheengineisthe
samepositionasthefuelhosethatwaspreviously
removed.

Figure8

1.Hoseclamp3.Waterseparator

2.Newfuelhose,connect
thisendtotheenginefuel
intake

Figure7

1.Existinglocknut6.Fuelselectorvalve

2.J-clamp

3.Engineframe

4.Existingwasher9.Hoseclamp

5.Existingbolt

7.Fuellter

8.Fuelhose

6.Installtheshorthosetothefrontrighthandfuel
tankconnection(Figure9).

7.Installthelongerhosetotherearrighthandfuel
tankconnection(Figure9).

Figure9

1.Righthandfueltank

2.Rearfueltankconnection5.Frontfueltankconnection

3.Hoseclamp

4.Longhose

6.Shorthose

8.Installthelongerfuelhosetothefrontlefthand
fueltankconnection.SeeFigure10.forthecorrect
hoses.

5

9.Installtheshorthosetothebacklefthandfueltank

G008099

1

2

G008999

1

G008998

1

connection(Figure10).

Figure10

1.Lefthandfueltank4.Shorthose

2.Rearfueltankconnection

3.Hoseclamp

5.Longhose

6.Frontfueltankconnection

10.Installtheplastictiestosecurethehosesfrom
touchinganyhotpartsofthemachineorrubbing
againstthemachine.

Figure11

1.Enginehood

2.Lowsulfurdecal

4.Cleantheexistingfrontdecalandtheareaaroundit
andletitdry(Figure12).

5.Installthenewdieseldecalovertheexistingone.
SeeFigure12.

5

InstallingtheDecalsandFuel
Caps

Partsneededforthisprocedure:

2

Lowsulfurdecal

2Fuelcap

1Dieseldecal

Procedure

1.Lowertheenginehood.

2.Removetheexistingdecaloneachside.

3.Installalowsulfurdecaloneachsideoftheengine
hood.SeeFigure4forthecorrectposition.

Figure12

1.Dieseldecal

6.Removebothexistingfuelcapsandreplacethem
withthenewfuelcaps(Figure13).

Figure13

1.Newfuelcap

6

Operation

6

VerifyingtheConnections

NoPartsRequired

Procedure

1.Openthefuelselectorvalve.

2.Openthewaterseparatordrainvalveuntilfuelstarts
todrainoutandclosethevalve(Figure14).

3.Ensuretherearenoleaksatthefuelhose
connections.

4.Installthenegativebatterycableontothebattery.

5.Starttheengineandensuretherearenoleaks.

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.

1.Waterseparator

2.Drainvalve

Figure14

3.Rightsideofmachine

•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.

Fuelisharmfulorfatalifswallowed.Long-term
exposuretovaporscancauseseriousinjuryand
illness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor
conditioneropening.

•Keepgasawayfromeyesandskin.

•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.

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.

•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfromafuel
dispensernozzle.

•Ifafueldispensernozzlemustbeused,keep
thenozzleincontactwiththerimofthefuel
tankorcontaineropeningatalltimesuntil
fuelingiscomplete.

8

Maintenance

ServicingtheFuelFilter

ChangingtheFuelFilter

ServiceInterval:Every400hours/Yearly(whichever

comesrst)(moreoftenindirtyor
dustyconditions).

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).

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.

1.Waterseparator

2.Drainvalve

Figure15

3.Rightsideofmachine

Figure16

1.Fuellter3.Rightsideofmachine

2.Hoseclamps

9

Notes:

10

Notes:

11