Toro 115-7490 Installation Instructions

DuelFuelPumpKit

forDFIZMaster

ModelNo.115–7490

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

®

Mowers

Installation

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

FormNo.3362-988RevA

InstallationInstructions

ProcedureDescription

1

2

3

Nopartsrequired

Fuelselectorvalvewithhosesandwire
harness

Hoseclamp2
Fuelselectorbracket1
Switch
Fuelpump1
Carriagebolt(1/4x3/4inch)
Carriagebolt(1/4x5/8inch)
Washer(1/4inch)
Nut(1/4inch)
Plastictie4
Coverplate
Fuelpumpbracket1
Lefthandfuelpumpbracket
Bolt(3/8x2-1/4inch)
Curvedwasher
Spacer
Bolt(3/8x7/8inch)
Flatwasher(3/8inch)
Shortfuelhose(3inch(7.6cm))
Longfuelhose
Hoseclamp10

Qty.

Use

–

1

1

2
2
4
4

1

1
2
2
2
2
2
2
1

Preparethemower.

Changingthefuelhoses.

Installthefuelpumps.

1

PreparingtheMower

NoPartsRequired

Procedure

1.Thoroughlycleanmower.Alldebrismustbe
removedtoensurethekitwilltproperly .

©2009—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Registeratwww.T oro.com.

2.Repairallbentordamagedareasandreplaceany
missingparts.

3.Drainthefuelfrombothfueltanks.

OriginalInstructions(EN)

PrintedintheUSA.

AllRightsReserved

2

ChangingtheFuelHoses

Partsneededforthisprocedure:

1Fuelselectorvalvewithhosesandwireharness

2Hoseclamp

1Fuelselectorbracket

1

Switch

Procedure

1.Loosenboththelefthandandrighthandlowerfuel
tankttingsandrotatethemforward.Keepthem
looseforeaseofassembly.

2.Removebothfuelhosesontherighthandfueltank
(Figure1).

Figure1

Righthandtankshown

Figure2

Lefthandtankshown

1.Lefthandfueltank

2.Upperfueltankconnection
(Donotremovehosehere)

3.Removehosehere

4.Disconnectthereturnhosefromtheengineatthe
fuelselectorvalve.Thisislocatedatthecentertop
port(Figure3).

5.Disconnectthelefthandtopfuelhoseatthefuel
selectorvalve.Thisislocatedatthelefthandtop
port(Figure3).

1.Righthandfueltank3.Lowerfueltankconnection

2.Upperfueltankconnection

3.Removethelowerfuelhoseonthelefthandfuel
tank.DoNOTremovethetopfuelhoseontheleft
handfueltank(Figure2).

Figure3

1.Returnhosefromthe
engine

2.Centertopport4.Lefthandtopport

3.Lefthandtopfuelhose

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

2.Hosefromthefuelselector
valvetofuellter

3.Wireharnessconnection

4.Hosefromthefuelpump
totheengine

5.Fuelpump

6.Hosefromthefuellterto
fuelpump

7.Fuellter

12.Installthefuelhosefromthetoplefthandfueltank
tothenewselectorvalveatthelefthandtopport
withanewhoseclamp.Ensuretheclampistight
(Figure5).

13.Installthereturnfuelhosefromtheenginetothe
newselectorvalveatthecentertopportwithanew
hoseclamp.Ensuretheclampistight(Figure5).

14.RoutethefuellinesasshowninFigure7.

15.Locatethelongerofthetwonewrighthandfuel
hosesattachedtothefuelselectorvalveassembly
andconnectittotheupperrighthandtanktting
(Figure7).

16.Installtheswitchintothebracketensuringthe
locatingpinonthebottomoftheswitchisonthe
leftsideoftheunit(Figure6).

Figure6

1.Righthandside

2.Locatingpin

3.Lefthandside

17.Installthenewfuelselectorvalvetothenewbracket
andconnectthewireharnesstotheswitch.

18.Installthenewbrackettothemachineusingthe
existingboltandnut(Figure7).

Figure5

1.Returnhosefromthe
engine

2.Centertopport4.Lefthandtopport

3.Lefthandtopfuelhose

3

1.Existingbolt

2.Existingnut

3.Routethehoses

Figure7

4.Newfuelselectorvalve

5.Upperrighthandfueltank
connection

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

2.Carriagebolt(1/4x3/4
inch)

3.Coverplate

4.Newfuelpump9.Wirescomingoutoffuel

5.Washer(1/4inch)

6.Locknut(1/4inch)

7.Fuelhose(3inch(7.6cm))

8.Hoseclamp

pump

2.Installashortfuelhosetothefuelpumpwithahose
clamponthesidethatthewiresdonotcomeout
ofthepump.

Note:Ensurethesmallfuelhoseisinstalledonthe
endofthefuelpumpthatdoesNOThavewires
comingoutofit.

3.Raiseuptherighthandsideofthemachineand
loweritontoajackstand.Removerighthandtire.

4.Removeboltsandnutsholdingtherighthandbrake
crossshaftbearingtotheframe.

Figure9

1.Existingnut

2.Rightsideofmachine5.Washer(3/8inch)

3.Newfuelpumpassembly6.Bolt(3/8x7/8inches)

4.Shortfuelhoseinstalled

7.Engagetheparkingbrake.

8.Onthelefthandsideofthemachine,removethe
upperfronttwofrontcarrierframebolts.

9.Installlefthandpumpbracketwith2spacers
betweenthecarrierframeandbracketusingthe
nutspreviouslyremovedand2newbolts(3/8x
2-1/4inches)and2newcurvedwashers(3/8inch)
(Figure10).

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.

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.

20.Connectnewwireharnesstotherighthandfuel
pumpandfoldanyextrawireanduseaplastictieto
securethefoldedwire(Figure12).

21.Plugthenewwireharnesstomainwireharnesson
unit.Thisisthesameconnectionthatwasusedfor
theexistingfuelpump(Figure12).

Figure11

1.Leftthandfuelpump
bracket

2.Washer(1/4inch)6.Existingfuelpump

3.Locknut(1/4inch)7.Carriagebolt(1/4x5/8

4.Hoseclamp

5.Fuelhose(3inch(7.6cm))

inch)

15.Connectthenewlongfuelhosetothelterandthe
engineusing2newhoseclamps.Ensurethehoseis
routedthesameastheonepreviouslyremoved.

16.Checkandtightenallboltsandallfuelhoseclamps.

17.Tightenbothlowerfueltankttings.

Figure12

1.Newharness

2.Existingmachineharness

3.Switch

22.Looselyinstallthefuelhoseassemblytothebrake
crossshaftasshownwith2plasticties(Figure13).

23.Useaplastictietosecurethefuelhosethrough
thecenterholesinthelefthandfuelpumpbracket
(Figure13).

18.Installtherighthandtire.Removethejackstand.

19.Routethenewwireharnesstothelefthandfuel
pumpthroughtheframefollowingthepathofthe
fuellineandconnectittothefuelpump.Keep
thefuelpumpwiresinsidethelefthandfuelpump
bracket.Pullthemtowardstherearandconnectthe
newwireharness(Figure12).

6

1.Brakecrossshaft

24.Filleachtankwithagallonoffuel.

25.Beforeoperatingthemachinecheckforleaksatall
hoseconnections.Ensurenofuelleaksoccurwhen
themachineisrstrun.

Figure13

2.Plasticties

7

Operation

UsingtheFuelSelectorValve
andSwitch

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

Theelectricalswitchmustbesettothesamefueltank
asthemechanicalfuelselectorvalve.

Figure14

1.Switch2.Mechanicalfuelselectorvalve

8