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manual abstract
Clamps require special pliers P/N 1- 643394 (Oetiker P/N 14100118 or Kohler P/N 2445505) for installation. Replacement Filters Kohler EFI Exmark P/N 99-9403 (low pressure) Kohler P/N 2405003 (high pressure) Kohler Air-cooled (except EFI) Kohler P/N 2405002 Note: When replacing the fuel filter for the Kohler EFI units, wet the interior of the new filter with gasoline before installation to prevent the high pressure pump from tearing the filter. Note: It is important to reinstall the fuel line hoses and secure with plastic ties the same as they were originally installed at the factory to keep the fuel line away from components that could cause fuel line damage. For Kohler EFI units: Route the fuel line hoses as shown in Figure 9. FIGURE 9 KOHLER EFI FUEL LINE ROUTING 5.1.24 Fuel pressure relief and priming procedure: (Kohler EFI units only) Service Interval: As required WARNING POTENTIAL HAZARD ¦ Fuel system components remain under high pressure, even when the engine is stopped. WHAT CAN HAPPEN ¦ Failure to relieve pressure from the system can cause gasoline to spray or spill. Spilled fuel or fuel vapors could be ignited by hot parts. HOW TO AVOID THE HAZARD ¦ Allow the engine to cool completely. ¦ Safely relieve the pressure from the fuel system before attempting to service the fuel system. A Kohler pressure gauge with an integral relief valve (Kohler Part No. 2445504) is recommended for relieving pressure and purging air in the fuel system. To relieve the system of pressure: a) Stop engine, wait for all moving parts to stop, and remove key. b) Allow the engine to cool completely. c) Connect the black tester hose from the Kohler pressure gauge to the test valve in the fuel rail. d) Route the clear hose into a portable gasoline container and depress the button on the tester relief valve. 5.1.25 Change hydraulic system filter: Service Interval: After First 250 hrs. Then yearly thereafter NOTE: Use only Exmark Part No. 1-513211 for summer use above 32° F (0°C) or Part No. 1-523541 for winter use below 32° F (0°C). a) Stop engine, wait for all moving parts to stop, and remove key. b) Raise seat. c) Carefully clean area around filter. It is important that no dirt or contamination enter hydraulic system. d) Unscrew filter to remove and allow oil to drain from reservoir. IMPORTANT: Before reinstalling new filter, fill it with Mobil 1 15W-50 and apply a thin coat of oil on the surface of the rubber seal. Turn filter clockwise until rubber seal contacts the filter adapter, then tighten the filter an additional 2/3 to 3/4 turn. e) Fill reservoir as stated in Section 5.1.12. f) Raise the rear of machine up and support with jack stands (or equivalent support) just high enough to allow drive wheels to turn freely. g) Start engine and move throttle control ahead to full throttle position. Move the speed control levers to the full speed and run for several minutes. Shut down machine and recheck oil level. Do not change hydraulic system oil (except for what can be drained when changing filter), unless it is felt the oil has been contaminated or been extremely hot. Changing oil unnecessarily could damage hydraulic system by introducing contaminates into the system. 5.1.26 Wheel hub - slotted nut torque specification. Service Interval: 500 hrs When tightening the slotted nut on the wheel motor tapered shaft: a) Torque the slotted nut to 125 ft. lbs (169 N-M). b) Check distance from bottom of slot in nut to inside edge of hole. Two threads (0.1”) or less should be showing. c) If more than two threads (0.1”) are showing remove nut and install washer (PN 1-523157) between hub and nut. d) Torque the slotted nut to 125 ft. lbs (169 N-M). e) Then tighten nut until the next set of slots line up with the cross hole in shaft. f) Replace cotter pin. NOTE: Do not use antisieze on wheel hub. 5.1.27 Fuel Tank – mounting hardware specification. When installing the nuts on the fuel tank studs, fully tighten the nyloc nut and back off 1/2 turn. This allows for normal fuel tank expansion and contraction with changes in temperature and fuel levels. 5.1.28 Thread locking adhesives such as “Loctite 242” or “Fel-Pro, Pro-Lock Nut Type” are used on the following fasteners: - 35 - a) Pump drive sheave set screws. b) Square head setscrews on Hydro pump control arms. c) Sheave retaining bolt in the end of engine crankshaft. d) Caster wheel spacer nuts e) Fuel tank bulkhead fitting nuts. f) Cutter housing spindle nut. Adhesives such as “Loctite RC/609 or RC/680” or “Fel-Pro Pro-Lock Retaining I or Retaining II” are used on the following: a) Fuel tank studs, where studs are inserted into tank. 5.1.29 Mobil HTS grease (or food-grade antisieze) is used in the following locations: a) Between the cutter housing spindle and bearings. b) Between the cutter housing spindle and sheave. c) Under top cutter housing bearing guard. d) Between jackshaft and bearings and jackshaft and sheaves. 5.1.30 Dielectric grease is used on all blade type electrical connections...