rework: kawasaki fuel filterfls.ixfr.com/144/136/z master_zrt113-rework-kawasaki_fuel...eng 12-02...

LANDSCAPE CONTRACTOR BUSINESS Z Master Zero Radius Tractors # 113 August 30, 2012

REWORK: Kawasaki Fuel Filter PRODUCT: Z Master® Zero Radius Tractors UNITS AFFECTED: Model Number(s):

74141 74141TE (Intl’) 74143 74941CP (Intl’) 74145 74943CP (Intl’) 74952 74945CP (Intl’) 74953 74955CP (Intl’) 74954 74957CP (Intl’) 74922 74902TE (Intl’) 78922 74925TE (Intl’) 74923 78924 74925 74927 74935 74937

SITUATION: Kawasaki Motor Company has informed Toro that the fuel filters on

certain Kawasaki engines may experience leaks. Poor welding allowed for gaps in the weld seam to occur, which could lead to a fuel leak.

Stop the sale of all eligible machines and loose (“replacement”) engines with the 49019-0707 fuel filter until rework is complete. Identifying information is contained within the Kawasaki FDM (attached).

WARRANTY: File warranty claim with Kawasaki per the attached Kawasaki FDM. - OVER -

Routing Svc Mgr Tech 1 Tech 2 Tech 3 Tech 4 Tech 5 Parts Mgr Sales Mgr Warranty Mgr

Initials

SERVICE BULLETIN

IMPORTANT SAFETY ALERT

LANDSCAPE CONTRACTOR BUSINESS Z Master Zero Radius Tractors # 113 (August 30, 2012) CORRECTION: Kawasaki Service Bulletin ENG 12-02 dated August 21, 2012 (enclosed),

covers the repair and warranty procedure. This is a MANDATORY REWORK to ensure product reliability. All Toro product shipped after August 20, 2012 has been reworked. Due diligence has been taken to ensure all product has been reworked, but we ask that dealers verify prior to sale. Reworked units can be identified by a Green Dot affixed to the serial plate and the carton barcode label.

Good filters can be identified by a Black Line on the body of the filter.

SERVICE

©2012, Kawasaki Motors Corp., U.S.A.

ENG 12-02NationalAugust 21, 2012

MODEL: SEE ELIGIBLE ENGINES TABLE

TITLE: FUEL FILTER (49019-0707) REPLACEMENT ON UNSOLD ELIGIBLE MACHINES AND LOOSE (“REPLACEMENT”) ENGINES

FACTORY DIRECTED MODIFICATION

See reverse side for additional information

REF:CODE:DATE:

REPLACES: Please Discard ENG 12-02 Dated August 20, 2012

Detail

Fuel filters within a certain date range may be faulty and have the potential to leak from the weld seam. A replacement filter has been made available to eliminate the possibility of a leak.

Kawasaki Action

Kawasaki has initiated a Factory Directed Modification (FDM) to modify all eligible unsold machines and unsold loose (“replacement”) engines according to the “Required Action” section of this Service Information. A corrective action plan for consumer units will follow upon the Consumer Product Safety Commission review and approval. For Service parts information please reference Stop Sale Notice ENG 12-01.

Stop the sale of all eligible machines and loose (“replacement”) engines with the 49019-0707 fuel filter until rework is complete. Identifying

information is contained within this notice.

Image 1: Fuel Filter (Part Number: 49019-0707)

ENG 12-02 Page 2

Eligibility

Engine Identification

Engine Model, Specification, and Serial Number are listed in the Eligible Engines Table on Pages 2 & 3. If your engine Model, Specification and Serial Number are listed and the fuel filter is within the specified date code range (see page 4 for date code identification and date code range), the engine is eligible for modification.

Eligible Engines Table

Model SpecStart EngineNumber

End EngineNumber

FE350D BS25 FE350D258796 FE350D273545FH381V DS21 FH381VA60977 FH381VA61136FH430V DS02, DS21, DS22 FH430VD07313 FH430VD08080FH480V DS21 FH480VA17627 FH480VA17690

FH541V DS01, ES20, ES21, ES22, ES31 FH541VB39319 FH541VB40710

FH580VCS33, CS39, DS01, DS37, ES20, ES21, ES22, ES23, ES29,ES35 FH580VC14255 FH580VC15330

FH601D AT50, FS01, FS05 FH601DA20574 FH601DA24240FH601V FS29, GS01, GS09, KS06 FH601VC40269 FH601VC40580FH641D FS01 FH641DA02279 FH641DA02326FH680D FS01, FS08 FH680DA39488 FH680DA40134FH680V ES28, ES32 FH680VC12339 FH680VC12518FH721D FS01, FS08 FH721DA57235 FH721DA57740

FH721V DS30, ES24, ES25, ES28, FS01 FH721VD67343 FH721VD67750

FH770D FS01, FS04 FH770DA17828 FH770DA17997FJ400D DS04, DS05, ES05 FJ400DB22137 FJ400DB46335

Model

Spec

Engine Serial Number

ENG 12-02

Eligible Engines Table (cont’d.)

Model SpecStart EngineNumber

End EngineNumber

FR541V AS50, AS51, AS52, BS04, CS00 FR541VA05747 FR541VA10514

FR600V AS50, AS51, BS06, BS08, CS00 FR600VA28739 FR600VA47566

FR651VAS18, AS19, BS11, BS12, BS13, BS16, BS17, BS52, CS05,CS06, CS08, CS09, CS10, CS50, CS51, ES00 FR651VB13474 FR651VB64183

FR691VAS17, AS18, AS19, BS13, BS14, BS50, CS07, CS09, CS12,CS51, CS52, DS05, ES00 FR691VB01958 FR691VB51951

FR730VAS12, AS13, AS14, AS15, AS16, BS10, CS05, CS07, CS09,DS04, ES00 FR730VA19372 FR730VA61003

FS481V

AE50, AS25, AS26, AS52, AS55, AS56, AS57, BS12, BS13,BS14, BS21, BS22, BS24, BS53, CS04, CS06, CS08, CS14,CS15, CS18, CS19, CS23, CS50, CS51, CT25, DS00, DS01,DS18, DS50

FS481VA30837 FS481VA73952

FS541V

AG80, AS23, AS24, AS25, AS26, AS27, AS52, AS53, BS16,BS51, CS05, CS06, CS08, CS10, CS11, CS19, CS21, CS50,DS00, DS01, DS19

FS541VA40673 FS541VA74103

FS600V

AE50, AS19, AS22, AS23, AS24, AS25, BS10, BS13, BS14,BS17, BS18, CS07, CS08, CS09, CS11, CS12, CS13, CS15,CT25, DS00, DS01

FS600VA08439 FS600VA55651

FS651VAG80, AG81, AS12, AS13, AS14, AS50, BS10, CS07, CS09,CS11, ES00

FS651VA27652 FS651VA48562

FS691VAS14, AS51, BS10, BS12, CS04, CS05, CS08, CS09, DS06,ES00 FS691VA07498 FS691VA13372

FS730V AS11, AS12, AS14, AS51, BS09, BS10, BS50, CS06, ES00 FS730VA18873 FS730VA36464FX481V DS00, DS04 FX481VA00810 FX481VA01191FX541V CS05, CS06 FX541VA00980 FX541VA01063

FX600VAS15, BS14, CS05, CS06, CS09, CS11, CS13, DS00, DS02,DS08, DS09

FX600VA14634 FX600VA18373

FX651V AS11, CS02, CS05, CS08, CS10, DS00, DS02, DS07, DS09 FX651VA16250 FX651VA22022

FX691VAS19, AS50, BS16, CS06, CS14, CS16, CS17, CS18, DS00,DS04, DS10, DS11, DS12, DS13 FX691VA18538 FX691VA29675

FX730V

AS18, AS19, AS20, BS14, CS03, CS06, CS07, CS08, CS09,CS12, CS13, CS15, CS16, CS17, DS00, DS03, DS04, ES05,FS05

FX730VA13811 FX730VA48607

FX751V CS04, DS04, DS05, ES00, FS07 FX751VA24127 FX751VA33598

FX801V AS09, AS11, CS06, CS07, DS06, DS08, ES00, FS04 FX801VA26410 FX801VA35509

FX850VAS13, AS14, AS15, BS01, CS04, CS11, CS12, DS04, DS07,DS10, ES00, ES09

FX850VA32209 FX850VA42326

FX921V AS09, AS10, BS07, CS05, CS08, DS04, DS05, DS06, ES00 FX921VA07267 FX921VA13450

FXT00V AS10, AS12, CS08, CS09, DS01, DS07, ES00, ES01 FXT00VA08783 FXT00VA11119

ENG 12-02

Date Code Identification

1. Check the date code of your filter. The date code format is DDD/YY where “DDD” is the Julian calendar day of manufacture, and “YY” is the two digit year of manufacture. Image 2 shows the location of the date code on the fuel filter.

2. Confirm that the date code on your filter is within the affected date range. Affected fuel filters have a date code in the ranges listed in the “Eligible Filters Table”. If the date code on your filter is included in this range, your engine is eligible for this modification.

NOTE: Some filters may have already been replaced by Kawasaki. If the filter has a black mark on the outside diameter of the fuel filter cap or if fuel filter is outside date code range the part is OK to use and does not need to be replaced. The mark is shown in Image 3.

Eligible Filters Table Year Date Code Range 2011 136/11 ~ 365/11 2012 001/12 ~ 216/12

Image 3: Black verification mark

Image 2: Fuel Filter Date Code Location

ENG 12-02

Required Action

For all eligible unsold units, replace the original fuel filter (Part Number 49019-0707) with the replacement filter (Part Number: 49019-0014) provided by Kawasaki. Follow the instructions in the Replacement Procedure section on Page 5.

Complete ENGINE APPLICATIONS AND REPLACEMENT ENGINES section of the FUEL FILTER EXCHANGE/PURCHASE ORDER FORM, Sign the completed form on the dealer signature line and fax to Kawasaki Order Services at 877-892-2700. If you already completed this form when you received the Stop Sale Notice ENG 12-01 please do not fax the form again.

When filing the warranty claim, the claim description must include the following sentence: "Date code of the original filter is DDD/YY and fuel filter has been destroyed and discarded."

Parts Information The affected fuel filter is shown in Image 1 on Page 1 above.

Replacement Procedure

WARNINGGasoline is extremely flammable and can be explosive under certain

conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes

any appliance with a pilot light.

Engine/Filter Confirmation – Confirm that your engine and fuel filter are eligible for this modification. If the filter has a black mark on the filter cap as shown in Image 3 on Page 4, the filter does not need to be replaced.

Replacement Part for FDM Parts Number Description Qty 49019-0014 Filter-Fuel 1

ENG 12-02

Fuel Filter Removal – Follow the instructions beginning on Page 6 to remove and replace the fuel filter.

1. Using pliers, move the two hose clamps away from the fuel filter.

2. Remove both fuel tubes from the fuel filter. Please be careful not to damage fuel tubes when removing original fuel filter. NOTE: The fuel tubes and fuel filter may contain excess fuel. Use caution when removing the fuel tubes. Keep tubes upright to prevent spills. Place paper towels underneath the fuel filter and tubes to catch any fuel spills.

Direction of Fuel Flow

ENG 12-02

3. Replace the fuel filter with new filter (Part Number: 49019-0014). Reattach both fuel tubes. Ensure that the direction of fuel flow is correct. The fuel tubes should be no more than 0.5 mm away from the fuel filter body. Rotate the new filter so that the black mark is visible.

4. Move the two hose clamps back to the fuel filter fittings. The clamps should be no more than 1.0 mm away from the end of each tube.

Fuel Filter Destruction – The old fuel filter must be made unusable before being discarded. Grip one of the fittings with a pair of pliers and twist until the fitting is removed from the filter. The process is shown in Images 4 & 5 below.When filing the warranty claim, include the following sentence in the claim description: “Fuel filter has been destroyed and discarded”.

Direction of Fuel Flow

Image 5: Destroyed fuel filter Image 4: Removal of the filter fitting

ENG 12-02

Warranty Information

The claim description must include the following sentence: "Date code of the original filter is DDD/YY and the fuel filter has been destroyed and discarded."Causal part number is 49019-0707. This FDM is acceptable only one time for each unit. Parts and labor costs will be reimbursed upon your warranty request. This FDM is for unsold eligible machines and loose (“replacement”) engines. A corrective action plan for consumer units will follow upon the Consumer Product Safety Commission review and approval.

ModelFE/FH/FJ/FR/FS/FX Engines

Flat Rate 0.3 Hours Trouble Code PC=C0 RC=31 Causal Part Filter, Fuel Causal Part No. 49019-0707 Quantity 1 Job Code 23722 Claim Type 3

Current qty. of unsold inventory (49019-0707) PO # (optional) KMC USE ONLY

ENGINE APPLICATIONS (on OEM equipment) AND REPLACEMENT ENGINES:Current qty. of unsold units PO # (optional) KMC USE ONLY

Tune-up Kit Item #Current qty. of unsold

inventory PO # (optional) KMC USE ONLY

99969-6189 (FR/FS)

99969-6190 (FR541/FR600)

99969-6191 (FX651/FX691/FX730)

99969-6196 (FX481/FX541/FX600)

99969-6220 (FH601/FH641/FH680/FH721)

Dealer # __________ Store Name____________________________________Contact Name____________________

Dealer Signature__________________________________________________ Date__________________________

S:GRAPHICS/E&PP/FORMS/ENG 12-02_OF ENG 12 02: Dated August 21, 2012

KAWASAKI MOTORS CORP., U.S.A. - ENGINE DIVISIONEXCHANGE / PURCHASE ORDER FORM

Complete form only for UNSOLD INVENTORY

If this form was sent when Stop Sale Notice ENG 12-01 was received, please do not resend

Fax completed form to 877.892.2700 (24/7)

KMC will ship the quantity of replacement filters noted above as soon as they become available. FDM Bulletin ENG 12-02 describes filter destruction and warranty claim instructions. Reimbursement will be provided through the normal warranty process.

KMC will ship the quantity of replacement kits noted above as soon as they become available. Upon receipt of this document acknowledging you have unsold kits in stock, KMC will fax RFC/Shipping Documents to you. Credit will be applied to your account once product is received by KMC.

KMC will ship the quantity of replacement filters noted above as soon as they become available. Destroy and discard service parts in accordance with the instructions outlined in STOP SALE Notice ENG 12-01. Your signature on this document acknowledges proper destruction and discard of the filter per the STOP SALE Notice ENG 12-01. Credit will be applied upon receipt of this signed form (allow for 3-5 business days for processing).

TUNE-UP KITS

REPLACEMENT FUEL FILTER (service parts)