Installation Instructions

ManualsBrandsToro ManualsRiding ProductsFuel Pump Replacement Kit, Diesel-Powered Traction Unit

FormNo.3449-487RevA

FuelPumpReplacementKit

Diesel-PoweredTractionUnit

ModelNo.144-4020

InstallationInstructions

Thiskitisformultiplemachines.Usetheloosepartstabletondyourmachineandtheprocedurenumber.

Conrmthemodelnumberforthemachineintheprocedure.

Safety

•Useextremecareinhandlingfuel.Itisammable

anditsvaporsareexplosive.

•Extinguishallcigarettes,cigars,pipes,andother

sourcesofignition.

•Useonlyanapprovedfuelcontainer.

•Donotremovethefuelcaporllthefueltank

whiletheengineisrunningorhot.

•Donotaddordrainfuelinanenclosedspace.

•Donotstorethemachineorfuelcontainerwhere

thereisanopename,spark,orpilotlight,such

asonawaterheaterorotherappliance.

•Ifyouspillfuel,donotattempttostarttheengine;

avoidcreatinganysourceofignitionuntilthefuel

vaporshavedissipated.

Installation

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

Qty.

Use

Nopartsrequired

–

Preparethemachine.

Fuelpump1

Fuellter

Hoseclamp4

Hose

61cm

(24

inches)

Installthefuelpumpona

Groundsmaster360machine.

Fuelpump1

Fuellter

Hoseclamp4

Bolt(1/4x5/8inch)

Nylonlocknut(1/4inch)

Hose

61cm

(24

inches)

Installthefuelpumpona

Groundsmaster3280machine.

Fuelpump1

Fuellter

Hoseclamp4

Self-tappingscrew(1/4x1/2inch)

Hose

61cm

(24

inches)

Installthefuelpumpona

Groundsmaster7200or7210machine.

8111LyndaleAvenueSouth

Bloomington,MN55420

Registeratwww.T oro.com.

OriginalInstructions(EN)

PrintedintheUSA

AllRightsReserved

*3449-487*

Summary of content (24 pages)

PAGE 1
Form No. 3449-487 Rev A Fuel Pump Replacement Kit Diesel-Powered Traction Unit Model No. 144-4020 Installation Instructions This kit is for multiple machines. Use the loose parts table to find your machine and the procedure number. Confirm the model number for the machine in the procedure. Safety • Do not add or drain fuel in an enclosed space. • Use extreme care in handling fuel. It is flammable • Do not store the machine or fuel container where and its vapors are explosive.
PAGE 2
Procedure 5 Description Qty.
PAGE 3
Procedure 12 Description Qty.
PAGE 4
Procedure 17 Description Fuel-pump plate Fuel pump Fuel filter Hose clamp Bolt (3/8 x 1 inch) Nylon locknut (3/8 inch) Self-tapping screw (1/4 x 1/2 inch) Hose Note: When installing the pump on any machine, inspect the fuel hose and replace it as needed. Qty. Use 1 1 1 4 2 2 1 61 cm (24 inches) Install the fuel pump on a Dingo TX525 machine.
PAGE 5
Use Figure 1 and Figure 2 for this procedure. Note: Install the fuel filter with the arrow pointing towards the fuel pump. g368968 Figure 1 1. Outlet towards the fuel pump 3. Inlet 2. Arrow points towards the fuel pump 1. Before removing the existing pump, clamp the fuel hose on both sides of the pump. This will prevent fuel leaking when replacing the pump. 2. Remove the existing fuel hoses from the fuel pump. 3. Remove the existing fuel pump from the machine and retain the hardware. 4.
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3 9. Install a hose clamp onto the existing fuel hose from the tank and install the fuel hose onto the new filter. Secure it with the hose clamp. 10. Plug the fuel-pump connector into the harness. Installing the Fuel Pump on a Groundsmaster 3280 Machine Parts needed for this procedure: 1 Fuel pump 1 Fuel filter 4 Hose clamp 2 Bolt (1/4 x 5/8 inch) 2 Nylon locknut (1/4 inch) 61 cm (24 Hose inches) Procedure This procedure is for machines with the following model numbers.
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4 9. Install a hose clamp onto the existing fuel hose from the tank and install the fuel hose onto the new filter. Secure it with the hose clamp. 10. Plug the fuel-pump connector into the harness. Installing the Fuel Pump on a Groundsmaster 7200 or 7210 Machine Parts needed for this procedure: 1 Fuel pump 1 Fuel filter 4 Hose clamp 1 Self-tapping screw (1/4 x 1/2 inch) 61 cm (24 Hose inches) Procedure This procedure is for machines with the following model numbers.
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5 Installing the Fuel Pump on a Groundsmaster 4000 Series Machine Parts needed for this procedure: 1 Fuel pump 4 Hose clamp 2 Carriage bolt (1/4 x 3/4 inch) 2 Nylon locknut (1/4 inch) 61 cm (24 Hose inches) Procedure This procedure is for machines with the following model numbers. Machine Model Number Groundsmaster 4100 30604 Groundsmaster 4000 30605 Groundsmaster 4010 30635 Groundsmaster 4110 30643 g368645 Figure 5 Use Figure 5 for this procedure.
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6 Installing the Fuel Pump on a Groundsmaster® 3500 Series Machine and a Reelmaster® 3100 or 3500 Series Machine 4. Install the new fuel pump to the fuel-pump plate with the 2 self-tapping screws (1/4 x 1/2 inch). 5. Install the new fuel pump and plate with the existing hardware to the engine block. 6. Install a hose clamp onto the fuel hose connected to the water separator and install it onto the new fuel pump. Secure the hose with the clamp. 7.
PAGE 10
onto the new fuel pump. Secure the hose with the clamp. 7 Installing the Fuel Pump on a Groundsmaster® 4500 or 4700 Machine and Reelmaster® 7000 Machine Parts needed for this procedure: 1 Fuel pump 1 Fuel filter 4 Hose clamp 7. Measure and cut a hose length to connect the fuel pump and fuel filter. 8. Install 2 hose clamps onto the hose. 9. Install the hose to the fuel pump and fuel filter and secure it with the 2 hose clamps. 10.
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8 Installing the Fuel Pump on a Groundsmaster 4300 Machine or a Reelmaster 5000 Series Machine 7. Install 2 hose clamps onto the hose. 8. Install the hose to the fuel pump and fuel filter and secure it with the 2 hose clamps. 9. Install a hose clamp onto the existing fuel hose from the tank and install the fuel hose onto the new filter. Secure the hose with the clamp. 10. Plug the fuel-pump connector into the harness.
PAGE 12
9 10. Install a hose clamp onto the existing fuel hose from the tank and install the fuel hose onto the new filter. Secure the hose with the clamp. 11. Plug the fuel-pump connector into the harness. Installing the Fuel Pump on a Reelmaster 6700 Machine Parts needed for this procedure: 1 Fuel pump 1 Fuel filter 4 Hose clamp 2 Bolt (1/4 x 5/8 inch) 2 Nylon locknut (1/4 inch) 61 cm (24 Hose inches) Procedure g368859 Figure 9 This procedure is for machines with the following model numbers.
PAGE 13
10 Installing the Fuel Pump on a Multi Pro® 5800 Machine Parts needed for this procedure: 1 Fuel pump 1 Fuel filter 4 Hose clamp 1 Spacer 61 cm (24 Hose inches) Procedure This procedure is for machines with the following model numbers. Machine Model Number Multi Pro 5800 41393 Use Figure 1 and Figure 10 for this procedure. Note: Install the fuel filter with the arrow pointing towards the fuel pump. 1. 2. Before removing the existing pump, clamp the fuel hose on both sides of the pump.
PAGE 14
11 Installing the Fuel Pump on a Workman® MDX-D Machine Parts needed for this procedure: 1 Fuel pump 1 Fuel filter 4 Hose clamp 2 Bolt (1/4 x 5/8 inch) 2 Nylon locknut (1/4 inch) 61 cm (24 Hose inches) g368817 Figure 11 Procedure This procedure is for machines with the following model numbers. 1. 9/32 inch hole 3. 44.5 mm (1-3/4 inches) 2. 28.6 mm (1-1/8 inches) 4. 63.5 mm (2-1/2 inches) 6.
PAGE 15
12 Installing the Fuel Pump on a Workman HDX-D Series Machine Parts needed for this procedure: g368861 Figure 12 1. Hose clamp 4. Locknut (1/4 inch) 2. Fuel-pump connector 5. Fuel pump 3. Fuel filter 6. Bolt (1/4 x 5/8 inch) 1 Fuel-pump bracket 1 Fuel pump 1 Fuel filter 4 Hose clamp 2 Bolt (1/4 x 5/8 inch) 2 Nylon locknut (1/4 inch) 1 Bolt (M8 x 20 mm) 61 cm (24 Hose inches) Procedure This procedure is for machines with the following model numbers.
PAGE 16
6. Install a hose clamp onto the existing fuel hose from the water separator and install it onto the new fuel pump. Secure it with the hose clamp. 7. Measure and cut a hose length to connect the fuel pump and fuel filter. 8. Install 2 hose clamps onto the hose. 9. Install the hose to the fuel pump and fuel filter and secure it with 2 hose clamps. 10. Install a hose clamp onto the existing fuel hose from the tank and install the fuel hose onto the new filter. Secure it with the hose clamp. 11.
PAGE 17
Z Master 7000, 152 cm cutting unit 74265TE Z Master 7000, 132 cm cutting unit 74264TE 12. Plug the fuel-pump connector into the harness. Use Figure 1, Figure 14, Figure 15, and Figure 16 for this procedure. Note: Install the fuel filter with the arrow pointing towards the fuel pump. 1. Before removing the existing pump, clamp the fuel hose on both sides of the pump. This will prevent fuel leaking when replacing the pump. 2. Remove the existing fuel hoses from the fuel pump. 3.
PAGE 18
14 Installing the Fuel Pump on a Greensmaster GR3250 Machine Parts needed for this procedure: 1 Fuel-pump bracket 1 Fuel pump 1 Fuel filter 4 Hose clamp 1 Bolt (1/4 x 5/8 inch) 1 Nylon locknut (1/4 inch) 61 cm (24 Hose inches) Procedure This procedure is for machines with the following model numbers. Machine Model Number Greensmaster GR3250 04384 Use Figure 1 and Figure 17 for this procedure. Note: Install the fuel filter with the arrow pointing towards the fuel pump. 1.
PAGE 19
15 Installing the Fuel Pump on a Greensmaster GR3400 and GR3420 Machine Parts needed for this procedure: 1 Fuel-pump plate 1 Fuel pump 1 Fuel filter 4 Hose clamp 2 Bolt (1/4 x 5/8 inch) 2 Nylon locknut (1/4 inch) 61 cm (24 Hose inches) Procedure This procedure is for machines with the following model numbers. Machine Model Number Greensmaster GR3400 04520 Greensmaster GR3420 04540 Use Figure 1 and Figure 18 for this procedure.
PAGE 20
9. Install the hose to the fuel pump and fuel filter and secure it with the 2 hose clamps. 10. Install a hose clamp onto the existing fuel hose from the tank and install the fuel hose onto the new filter. Secure it with the hose clamp. 11. Plug the fuel-pump connector into the harness.
PAGE 21
g369878 g369033 Figure 19 1. 9/32 inch hole 3. 3.2 mm (1/8 inches) 2. 63.5 mm (2-1/2 inches) 5. Using the new holes, install the new fuel pump with 2 bolts (1/4 x 5/8 inch) and 2 locknuts (1/4 inch). 6. Install a hose clamp onto the existing fuel hose from the engine and install it onto the new fuel pump. Secure it with the hose clamp. 7. Measure and cut a hose length to connect the fuel pump and fuel filter. 8. Install 2 hose clamps onto the hose. 9.
PAGE 22
17 Installing the Fuel Pump on a Dingo TX525 Machine Parts needed for this procedure: 1 Fuel-pump plate 1 Fuel pump 1 Fuel filter 4 Hose clamp 2 Bolt (3/8 x 1 inch) 2 Nylon locknut (3/8 inch) 1 g369032 Figure 21 Self-tapping screw (1/4 x 1/2 inch) 61 cm (24 Hose inches) 1. 13/32 inch hole 3. 33 mm (1-5/16 inches) 2. 13 mm (1/2 inch) 4. 51 mm (2 inches) 5. Install the new fuel pump to the fuel-pump bracket with 2 self-tapping screws (1/4 x 1/2 inch). 6.
PAGE 23
g369031 Figure 22 1. Fuel-pump connector 5. Fuel filter 2. Hose clamp 6. Locknut (3/8 inch) 3. Bolt (3/8 x 1 inch) 7. Fuel pump 4. Fuel-pump plate 8.
PAGE 24