Toro 105-9363 Installation Instructions

Fuel Tank Fittings Kit

200 Series Z Master with Electronic Fuel Injection

Part No. 105–9363

Installation Instructions

Loose Parts

Note: Use the chart below to identify parts for assembly.

DESCRIPTION QTY. USE

Form No. 3327–622

Fuel Bulkhead—with screen Fuel Bulkhead—without screen Hose Grab Tool Thread locker Hose clamp, 1/4 in. Hose clamp, 5/16 in.

Hose clamp, 5/16 in. 1 Draining the Fuel Tank

Draining The Fuel Tank

Warning

Gasoline is harmful or fatal if swallowed. Long–term exposure to vapors can cause serious injury and illness.

• Avoid prolonged breathing of vapors.

• Keep face away from nozzle and gas tank or

conditioner bottle opening.

• Keep gas away from eyes and skin.

Danger

2 2 1 1 1 4 1

Installing the bulkhead fittings

Note: Fuel tanks hold up to 6 gallons of fuel each.

Important Removal and installation of hose clamps

requires special pliers. Contact an Authorized Kohler Service Dealer for ordering pliers.

1. Park the machine on a level surface, to ensure the fuel

tank drains completely. Then disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key.

2. Close the fuel shut–off valve (Fig. 1).

3. Remove the hose clamp at the fuel filter.

4. Pull the fuel line off fuel filter. Open fuel shut-off

valve and allow gasoline to drain into a gas can or drain pan.

In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property.

• Drain gasoline from the fuel tank when the

engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills.

• Never smoke when draining gasoline, and stay

away from an open flame or where a spark may ignite the gasoline fumes.

 2002 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

5. Repeat these procedures for the opposite fuel tank.

6. Install the fuel line onto the fuel filter using a new

hose clamp (5/16 in.).

Note: Now is the best time to install a new fuel filter because the fuel tank is empty.

Printed in the USA

Installing the Bulkhead Fittings

Note: The bulkhead fittings with the screens need to be installed in the bottom of the fuel tank. Install bulkhead fittings in both tanks.

Figure 1

1. Fuel shut-off valve

Removing the Existing Grommets

Note: There are two grommets in each fuel tank. There is a grommet located on the side and bottom of the fuel tank.

1. Remove the hose clamps from the grommets and then

remove the hoses.

2. Using a pliers, remove the existing fitting and

grommet from the bottom of the fuel tank (Fig. 2).

3. Using a pliers, remove the existing fitting and

grommet from the side of the fuel tank.

Note: Remember to remove both the bottom and side grommets and fittings. Ensure all of the grommet is removed from the fuel tank.

1. Push the installation hose up through the bottom hole

in the fuel tank (Fig. 3).

2. Using the grab tool, reach down through the filler neck

and pull the hose up through the filler neck (Fig. 3).

3. Remove the nut and washer from the bulkhead fitting. Note: Make sure the rubber o–ring is retained in the

groove of the bulkhead fitting.

4. Attach the installation hose onto the elbow of the

bulkhead fitting (Fig. 3).

5. Pull the hose and bulkhead fitting back down into the

fuel tank. Pull the hose until the elbow is through the bottom (Fig. 3).

1 2 3

1. Rubber grommet—bottom

2. Fitting—bottom

3. Fuel tank

Figure 2

4. Rubber grommet and fitting—side

m–5830

m–5828

Figure 3

1. Bulkhead fitting

2. Installation hose

3. Grab tool

4. Fuel tank

6. Pull the bulkhead fitting through the hole until the

threads are showing (Fig. 4).

7. Remove the installation hose. Apply thread locking

compound onto the threads of the fitting.

8. Install the washer and locknut onto the fitting. Position

the elbow in the correct position, for the fuel line, and tighten the locknut (Fig. 4).

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