Toro 115-3564 Installation Instructions

Bio-DieselKit

2006andBeforeKubota

ModelNo.115–3564

Thiskitisformachineswithaserialnumberof
269999999andBelow .

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

FormNo.3360-696RevA

®

-PoweredZMaster

®

RidingMowers

InstallationInstructions

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

•Wipeupanyfuelthatspills.

•Neverllthefueltankinsideanenclosed
trailer.

Fuelisharmfulorfatalifswallowed.Long-term
exposuretovaporscancauseseriousinjuryand
illness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor
conditioneropening.

•Keepfuelawayfromeyesandskin.

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1

2

3

4

5

Fuelselectorvalvewithhoses1

Template(locatedinthebackofthese
instructions)

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
Hose1
Hoseclamp8
Fuelpumpharness1
Lowsulfurdecal
Fuelcap2
Dieseldecal1

•Neversmokewhenhandlingfuel,andstay
awayfromanopenameorwherefuel
fumesmaybeignitedbyaspark.

Qty.

Installthenewfuelselectorvalve.

1

1
1
1

1
1
2

2

Drillholesforthewaterseparatorand
fuelpumpbrackets.

Installthewaterseparatorandfuel
pump.

Connectthefuelhosesandthefuel
pumpharness.

Installthedecalsandfuelcaps.

Use

6

©2008—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Nopartsrequired

Registeratwww.Toro.com.

–

Verifytheconnections.

OriginalInstructions(EN)

PrintedintheUSA.

AllRightsReserved

8.Todrainthefueltank,placeacleancontainerunder

000

0000

0000

thefrontfueltankconnection,removethefuelhose

1

fromtheconnectionorcutthefuellineanddirect
thefuellineintothecontainer(Figure2).

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).

9.Allowthefueltodrainintothecontainerandwipe
upanyspilledfuel.Ensurethefuellineisremoved
fromthetankconnection(Figure2).

10.Drainthefuelfromtheoppositetank.

Figure2

1.Righthandfueltank
shown

2.Rearfueltankconnection

3.Frontfueltankconnection

11.Followthefuelhosesfromtheexistingselector
valveandremovethehosesfromthefuellterand
thefueltanks.

12.Disconnecttheelectricalconnectionforthefuel
pumpfromthemainwireharness.Rememberthe
locationofthisconnectionbecauseitwillbeused
forthenewfuelpump.

13.Removetheexistingfuelhosefromtheengineand
removetheexistingfuelltersfromthemachine
(Figure3).

Figure3

2.Fuelhoseconnectedto
engine

Figure1

1.Knob2.Frontenginepanel

1.Existingfuellters

14.Removetheexistingfuelselectorvalve.Referto
Figure4.Savetheexistingsoftware.

2

Figure4

1.Hosetoremove

15.Usingthepreviouslyremovedhardware,installthe
newfuelselectorvalve(Figure5).

2.Closefuelselectorvalve

2.Removethenutsandboltsholdingthehoodsupport
bracket.Savethenutsandbolts(Figure6).

3.Removetheboltforthetopengineguardstrapfrom
themachine(Figure6).

Figure6

1.Removethesenutsand
boltsfromthehood
supportbracket

2.Removethisboltfromthe
topengineguardstrap

3.Hoodsideplate

Figure5

1.Newfuelselectorvalve

2.Bracket4.Existingnut

3.Existingwasher

2

DrillingHolesfortheWater
SeparatorandtheFuelPump
Brackets

Partsneededforthisprocedure:

4.Usingthepapertemplateinthebackofthese
instructions,markanddrill2holes(11/32inch
diameter)intothehoodsupportbracket(Figure7).

5.Drilla17/64inchdiameterholeintotheexisting
holeintheengineguardstrap(Figure7).

1

Template(locatedinthebackoftheseinstructions)

Procedure

1.Raisethehoodontheengine.

3

2.InstallthesmallR-clamparoundthefuelpumpand
installittotheenginestrapwithabolt(1/4x1–1/4
inches)andnut(1/4inch)(Figure8).

Figure7

1.Hoodsideplate4.Template

2.Drilla17/64inchholeinto
theexistinghole

3.Enginestrap

5.Drilltwo11/32inchholes
intothehoodsupport
brackethere

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

Figure8

1.SmallR-clampwithfuel
pumpinstalled

2.Locknut(1/4inch)

3.Bolt(1/4x1–1/4inches)

3.InstallthewaterseparatorintothelargeR-clamp
andinstallittothehoodsupportbracketwithabolt
(5/16x1-3/4inches),abolt(5/16x3/4inch),and
2locknuts(5/16inch)(Figure9).

Procedure

1.Routethefuellterandfuelpumptowardsthe
backoftheengine.Makesurenopartsorhosesare
touchingthemachineinareasthatwillgethot.

4

Figure9

G008098

3

2

1

5

6

5

4

7

1.LargeR-clampwithwater
separator

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

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

4

ConnectingtheFuelHoses
andtheFuelPumpHarness

Figure10

1.Fuelpump5.Hoseclamp

2.Fuellter

3.Valveselector7.Fuelpumpharness

4.Hose

5.Installthefabricsleeveontherighthandtankhoses.
SeeFigure11forthecorrecthoses.

6.Waterseparator

Partsneededforthisprocedure:

1Hose

8Hoseclamp

1Fuelpumpharness

Procedure

1.Installthehoseinstalledonthefuelpumptothe
waterseparatorwithahoseclamp.SeeFigure10
forthecorrectconnectiontouseonthetopofthe
waterseparator.

2.Installthehosetothewaterseparatorandtothe
enginefuelintakewith2hoseclamps(Figure10).

3.Installtheelectricalfuelpumpwiretothefuelpump
harness.

4.Installthefuelpumpharnesstothemainwire
harness(Figure10).

6.Installthehoseswiththefabricsleeveintothetwo
R-clamps(Figure11).

7.Installthelongerhosetothefrontrighthandfuel
tankconnection(Figure11).

8.Installtheshorthosetothebackrighthandfueltank
connection(Figure11).

5

000

0000

0000

Figure11

G008099

1

2

1.Righthandfueltank

2.R-clamp5.Hoseclamp

3.Fabricsleeve6.Fueltankconnection

4.Fuelselectorvalve

5

InstallingtheDecalsandFuel
Caps

Partsneededforthisprocedure:

2

Lowsulfurdecal

2Fuelcap

1Dieseldecal

Procedure

9.Installthelongerfuelhosetothefrontlefthand
fueltankconnection.SeeFigure12.forthecorrect
hoses.

10.Installtheshorthosetothebacklefthandfueltank
connection(Figure12).

Figure12

1.Fuelselectorvalve

2.Hoseclamp

3.Fueltankconnection

4.Longfuelhose

5.Shortfuelhose

1.Lowertheenginehood.

2.Removetheexistingdecaloneachside.

3.Installalowsulfurdecaloneachsideoftheengine
hood.SeeFigure13forthecorrectposition.

Figure13

1.Enginehood

2.Lowsulfurdecal

4.Cleantheexistingfrontdecalandtheareaaroundit
andletitdry(Figure14).

5.Installthenewdieseldecalovertheexistingone.
SeeFigure14.

6

G008999

1

G008998

1

6

VerifyingtheConnections

NoPartsRequired

Figure14

1.Dieseldecal

6.Removebothexistingfuelcapsandreplacethem
withthenewfuelcaps(Figure15).

Figure15

1.Newfuelcap

Procedure

1.Openthefuelselectorvalve.

2.Openthewaterseparatordrainvalveuntilfuelstarts
todrainoutandclosethevalve(Figure16).

3.Ensuretherearenoleaksatthefuelhose
connections.

4.Installthenegativebatteryontothebattery.

5.Starttheengineandensuretherearenoleaks.

Figure16

1.Drainvalve

2.Waterseparator

3.Backofmachine

7

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.

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.

Important:Donotusekeroseneorgasoline
insteadofdieselfuel.Failuretoobservethis
cautionwilldamagetheengine.

•Ifafueldispensernozzlemustbeused,keep
thenozzleincontactwiththerimofthefuel
tankorcontaineropeningatalltimesuntil
fuelingiscomplete.

8

FillingtheFuelTank

Fuelisharmfulorfatalifswallowed.Long-term
exposuretovaporscancauseseriousinjuryand
illness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor
conditioneropening.

•Keepgasawayfromeyesandskin.

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.

9

Maintenance

ServicingtheFuelFilterand
WaterSeparator

ServiceInterval:Every40hours—Drainthewater

separator.

Every400hours/Yearly(whichever
comesrst)—Replacethefuel
lter(moreoftenindirtyordusty
conditions).

ChangingtheFuelFilter

Neverinstalladirtyfuellterifitisremovedfromthe
fuelline.

1.Allowthemachinetocooldown.

2.DisengagethePTO ,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

3.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

4.Closethefuelshut-offvalve(Figure18).

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).

5.Loosenthetwohoseclampsanddisconnectthefuel
linesfromthefuellter(Figure18).

6.Installanewlter.Connectthefuellinestothefuel
lterandinstallthetwohoseclamps(Figure18).

7.Openthefuelshut-offvalve.

8.Starttheengineandcheckforleaks.

1.Drainvalve

2.Waterseparator

Figure17

3.Backofmachine

Figure18

1.Fuellter4.Leftsideofmachine

2.Hoseclamp

3.Fuelpump

10

5.Fuelshut-offvalve

11