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Line Painter 1200

1. Oil Capacity Including Oil Filter 0 9 Quart 0 85 Liter Air Cleaner Dual Element Ignition System Flywheel Magneto CDI Spark Plug NGK BPR5ES Spark Plug Gap 028 to 032 7 to 8 mm Dry Weight 35 3 Pounds 16 Kilograms Line Painter 1200 Page 3 3 Gasoline Engine o 7 G o General Information Fuel Shut off Valve The fuel shut off valve is positioned in the fuel hose be tween the fuel tank and the carburetor inlet It has two positions CLOSED and OPEN Turn valve to the closed position when storing or transporting the machine Ro tate valve to the open position before starting the en gine Figure 1 1 Fuel shut off valve Gasoline Engine Page 3 4 Line Painter 1200 Service and Repairs Cooling System IMPORTANT The engine that powers the Line Painter 1200 is air cooled Operating the engine with dirty or plugged cooling fins or a plugged or dirty blower housing will result in engine overheat ing and damage 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug IMPORTANT Never clean engine with pressurized water Water could enter and contaminate the fuel system og Su 2 Remove rewind starter and clean rotating screen Fig 2 Figure 2 1 Rotat
2. 6 Before disconnecting any paint system component or performing any work on the paint system all pressure in system must be relieved 7 Do not use lacquers lacquer thinners acetones or other solvents when servicing the paint system of the Line Painter 1200 Line Painter 1200 Page 1 3 8 Do not overspeed the engine by changing governor setting To assure safety and accuracy check maximum engine speed with a tachometer 9 Shut engine off before checking or adding oil to the engine crankcase 10 To reduce potential fire hazard keep engine area free of excessive grease grass leaves and dirt 11 1f major repairs are ever needed or assistance is de sired contact an Authorized Toro Distributor 12 When changing tires or performing other service make sure machine is properly supported If the ma chine is not properly supported the machine may move or fall which may result in personal injury 13 At the time of manufacture the machine conformed to all applicable safety standards To assure optimum performance and continued safety certification of the machine use genuine Toro replacement parts and ac cessories Replacement parts and accessories made by other manufacturers may result in non conformance with the safety standards and the warranty may be voided Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Line Painter 1200 If any decal becomes illegible or
3. C Secure wheel to transaxle shaft with washer item 7 and e ring item 6 3 Carefully lower machine to ground 4 Secure high tension lead to spark plug Line Painter 1200 Page 6 7 N Figure 5 Outside bearing Bushing Rim and tire assembly 4 Grease fitting 5 Bearing 6 Valve stem Chassis and Controls O Sa og Ne 0 co 9 Brake Cable Brake Cable Attachment Point Note Console shown removed from handle for clarity 7 Hairpin 8 Flange nut Figure 6 1 Brake lever 4 Shoulder screw 2 Knob 5 Handle assembly 3 Compression spring 6 Brake cable Removal Fig 6 1 Park machine on a level surface stop engine and re move key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug Chock wheels to prevent machine from moving during brake cable repair 2 Disconnect brake cable from brake lever Fig 6 A Loosen jam nut that secures cable to handle as sembly B Remove hair pin that retains cable end to brake lever C Slide cable end from brake lever Chassis and Controls Page 6 8 3 Disconnect brake cable from brake lever on trans axle Fig 7 A Loosen jam nuts that secure cable to chassis bracket B Disconnect cable spring from brake lever 4 Note routing of brake cable Remove cable from ma chine Installation Fig 6 1 Position brake cable to machine Line Painter 1200
4. Chassis 9 Connect shift linkage to shift lever on transaxle see Shift Lever and Linkage in this section 10 Lower machine to ground 11 Secure high tension lead to spark plug 12 Verify that machine will track in a straight line If nec essary adjust front castor fork see Front Castor Fork Adjustment in Chapter 6 Chassis and Controls Traction Drive System o 2 Ta a c e S ped o D gt 2 Transaxle Service 30 to 40 in lb P 1 2 3 4 to 4 5 N m 240 to 300 in Ib 27 1 to 33 9 N m 160 to 200 in Ib 6o 18 1 to 22 6 N m Figure 5 Traction Drive System Page 7 8 Line Painter 1200 Screw Detent cover Detent spring 2 used Detent ball 2 used Cap plug Shifter boot Screw 16 used Upper housing Shifter 10 Retaining ring 11 Shim washer 12 Plain washer 13 Washer 14 Bearing 15 Woodruff key 16 Input shaft 17 Bevel pinion gear 12T 18 Retaining ring 19 Flange bearing 20 Washer 21 Spacer 22 Spur gear 31T 23 Spur gear 23T BOND AN NOTE For service of the transaxle see the Dana Mod el 4360 Teardown and Reassembly Instructions at the end of this chapter Line Painter 1200 Figure 5 Continued Spur gear 15T Drive shaft Shim washer Bevel gear 36T Sprocket 9T Spacer Washer Chain Woodruff key Intermediate shaft Clutch key Clutch collar Spur gear 12T Retaining
5. 3 Connect traction drive cable to traction idler bracket under machine Fig 12 A Connect cable spring to idler bracket Figure 12 B Position cable to chassis bracket C Adjust traction drive cable see Traction Drive 7 ME ed table 3 3 idler bracket Cable in the Adjustments section of this chapter D Make sure that cable boot is positioned over end of cable 4 Secure high tension lead to spark plug ie Sao og oc 20 co 9 Line Painter 1200 Page 6 13 Chassis and Controls Paint Control Cable Figure 13 1 Paint control lever 4 Flange nut 7 Rubber bumper 2 Bushing 5 Hair pin 8 Cap screw 3 Bushing 6 Paint control cable 9 Flat washer Removal Fig 13 3 Disconnect paint control cable from paint shutoff valve Fig 14 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition A Loosen jam nuts that secure cable to chassis switch Remove high tension lead from the spark plug bracket and position the lead away from the spark plug B Remove two 2 pins that secure paint shutoff 2 Disconnect paint control cable from paint control valve lever to shutoff valve Shift position of lever to lever on machine handle allow cable clevis removal A Loosen jam nut that secures cable to handle as C Remove hair pin and clevis pin that secure cable sembly clevis to paint shutoff valve lever B Remove hair pin that retains cable end to pai
6. 4 Castor plate If the Line Painter 1200 does not follow a straight line when the castor detent is engaged front castor fork ad justment is necessary Adjustment 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug 2 Make sure that castor lever on handle is released to lock the castor fork in position NOTE Shorten a 1 4 allen wrench Fig 3 to allow ac cess to socket head screws item 2 that secure castor plate If modified allen wrench is not available remove front wheel to access socket head screws 3 Loosen two 2 socket head screws item 2 that se cure castor plate to castor fork Chassis and Controls 3 Lock washer 2 used Page 6 4 5 Castor fork 4 Rotate castor fork until wheel is in proper position for straight line tracking 5 Tighten two 2 socket head screws to secure castor fork assembly 6 Secure high tension lead to spark plug 7 Operate machine to make sure it follows a straight line Readjust castor fork if necessary 1 4 ALLEN WRENCH fee u j Figure 3 Line Painter 1200 This page is intentionally blank O Sa og Ne 0 co 9 Line Painter 1200 Page 6 5 Chassis and Controls Service and Repairs Wheels ANTISEIZE LUBRICANT Figure 4 1 Front castor wheel 5 Lock nut 9 Square key
7. 8 Support transaxle to prevent it from falling 9 Remove four 4 flange nuts item 2 and carriage screws item 8 that secure transaxle to machine 10 Lower transaxle from machine 11 If necessary remove external snap ring item 14 and drive pulley item 13 from transaxle input shaft Lo cate and retrieve woodruff key not shown Line Painter 1200 Installation Fig 4 1 Chock front castor wheel Raise machine so that rear of machine is off the ground Support machine to pre vent it from shifting during transaxle installation 2 If drive pulley was removed from transaxle input shaft apply antiseize lubricant to input shaft Position woodruff key not shown in input shaft keyslot Slide drive pulley onto shaft and secure with snap ring item 14 3 Raise transaxle to machine frame 4 Secure transaxle to machine frame with four 4 car riage screws and flange nuts 5 Install rear wheels see Wheel Installation in the Ser vice and Repairs section of Chapter 6 Chassis 6 Install traction drive belt to transaxle pulley see Traction Drive Belt Installation in this section Make sure that traction belt guides are positioned from 060 to 130 1 5 to 3 3 mm from installed belt Line Painter 1200 Page 7 7 7 Connect brake return spring item 7 to brake lever on transaxle 8 Connect brake cable to transaxle see Brake Cable Installation in the Service and Repairs section of Chap ter 6
8. Pump drive belt 4 Engine pulley Gasoline Engine o E a o o o a ul This page is intentionally blank Gasoline Engine Page 3 10 Line Painter 1200 Chapter 4 TORO Electrical System Table of Contents ELECTRICAL SCHEMATIC sss 2 SPEGIAL TOOLS APAN aad tas 3 TROUBLESHOOTING 0 se se eed de ee 4 COMPONENT TESTING id ee ee ee ee 5 On Off Switch EE EE EE ee ee ee ee 5 Hourmeter Optional an 6 SE 2 sy 9 2H LU Line Painter 1200 Page 4 1 Electrical System Electrical Schematic HIGH TENSION LEAD HR HOUR METER OPTIONAL ENGINE MAGNETO FLYWHEEL A ON OFF SWITCH is open in the ON position ON OFF SWITCH Electrical System Page 4 2 Line Painter 1200 Special Tools Multimeter The multimeter can test electrical components and cir cuits for current amps resistance ohms or voltage NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Figure 1 Spark Tester TOR4036 The spark tester can test magneto ignitions The spark tester determines if ignition is present Electrical Figure 2 Line Pain
9. 2 Bushing 6 E ring 10 Thrust washer 3 Cap screw 7 Washer 11 Spacer 4 Castor fork 8 Rear wheel Chassis and Controls Page 6 6 Line Painter 1200 Removal Fig 4 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug 2 Raise machine so that wheel to be removed is off the ground Support machine to prevent it from shifting dur ing wheel removal 3 To remove front wheel A Remove lock nut item 5 and cap screw item 3 that secure wheel to castor fork B Slide wheel from castor fork C Remove front wheel bushing and bearings as needed Fig 5 4 To remove rear wheel A Remove e ring item 6 and washer item 7 that secure wheel to transaxle shaft B Slide wheel from transaxle shaft C Locate and retrieve square key item 9 Installation Fig 4 1 To install front wheel A If front wheel bushing and bearings were re moved install bushing and bearings to wheel as sembly Fig 5 B Position front wheel to castor fork C Install cap screw item 3 and lock nut item 5 to secure wheel to castor fork D Lubricate grease fitting on front wheel see Oper ator s Manual 2 To install rear wheel A Apply antiseize lubricant to transaxle shaft Posi tion square key item 9 in transaxle slot B Slide wheel onto transaxle shaft
10. 21 Rev A 7 Connect extension spring item 9 to lever 8 Connect inlet and outlet hoses to paint shutoff valve Fig 19 see Quick Disconnect Fitting in the General In formation section 9 Install flush tank see Flush Tank Installation in this section 10 Secure high tension lead to spark plug Figure 19 1 Cable 3 Inlet hose 2 Outlet hose 4 Paint shutoff valve Figure 20 1 Pivot cotterless pin 2 Spool cotterless pin Figure 21 1 Manifold block 4 O ring 2 Spool 5 O ring 3 O ring Paint System Pressure Regulator 144 to 156 in Ib 16 3 to 17 6 N m 120 to 132 in Ib 13 6 to 14 9 N m Figure 22 4 Tee fitting 5 Tank support 6 Elbow fitting 1 Pressure regulator 2 Flange head screw 2 used 3 Straight fitting Removal Fig 22 1 Drain paint tank see Operator s Manual Operate line painter in the flush mode to clean paint tubes 2 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug 3 Remove flush tank see Flush Tank Removal in this section 4 If equipped remove pressure gauge from machine Paint System Page 5 22 7 Bracket 8 Cap screw 5 Label hoses connected to pressure regulator to as sist in assembly Remove hoses from fittings
11. 22 622 13 32 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7 16 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 046875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 mm 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sa In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Maintenance Page 2 2 Line Painter 1200 T
12. 5 12 3 Loosen nut that secures drain valve to tank Fig 5 4 Remove two 2 flange head screws item 16 that secure drain valve to valve bracket Remove nut from drain valve and remove valve from machine Retrieve o ring item 12 from outside tank 5 Remove agitation tube from elbow fitting Fig 5 see Quick Disconnect Fitting in the General Information sec tion Loosen and remove elbow fitting Line Painter 1200 6 Remove two 2 jam nuts that secure tank to ball valve ports Fig 5 Locate and retrieve washers items 4 and 20 7 Remove four 4 flange head screws item 17 that secure tank to tank support 8 Lift tank from machine Locate and retrieve rubber washers item 8 that seal tank to ball valve ports Dis card washers 9 If necessary remove tank lid flange using Figure 6 as a guide Installation Fig 4 1 Place new rubber washers item 8 on ball valve ports 2 Position tank on ball valve ports 3 Loosely install the following components A Valve fitting washers items 4 and 20 and jam nuts item 5 B Drain valve o ring item 12 and nut item 2 C Four 4 flange head screws item 17 4 Torque jam nuts item 5 from 192 to 216 inb 21 7 to 24 4 N m 5 Tighten drain valve nut item 2 to secure drain valve to tank Then tighten two 2 flange head screws item 16 that secure drain valve to valve bracket Finally tight en the four screws item 17 to secure tank t
13. Castor wheel 6 Castor fork 11 Chassis 2 Bushing 7 Cap screw 12 Wave washer 3 Socket head screw 2 used 8 Castor plate 13 Rebound washer 4 Lock washer 2 used 9 Bushing 14 Flange head screw 5 Lock nut 10 Grease fitting Removal Fig 16 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug 2 Raise front of machine to allow front castor fork re moval Support machine to prevent it from shifting dur ing repair 3 Depress castor release lever to disengage caster detent from castor fork 4 Remove castor wheel from castor fork see Wheel Removal in this section Chassis and Controls Page 6 16 5 Remove flange head screw item 13 rebound washer item 12 and wave washer item 11 6 Lower castor fork from chassis 7 If necessary remove two 2 socket head screws item 3 and lock washers item 4 that secure castor plate to castor fork 8 If necessary remove bushing s item 9 from chas sis Line Painter 1200 Installation Fig 16 1 If removed install bushing s item 9 into chassis 2 If removed install castor plate to castor fork with two 2 socket head screws item 3 and lock washers item 4 3 Coat stem of castor fork with grease Slide fork into chassis 4 Position wave washer item 11 and rebound washer item 12 to to
14. Clevis pin m S 5 Spacer 10 Castor release cable 8 Line Painter 1200 Page 6 11 Chassis and Controls Traction Drive Cable Figure 11 1 Traction lever 5 Traction drive cable 8 Bushing 2 used 2 Flat washer 6 Hair pin 9 Bushing 3 Cap screw 7 Flange nut 10 Castor release lever 4 Flange bushing Removal Fig 11 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug 2 Disconnect traction drive cable from traction lever on machine handle A Loosen jam nut that secures cable to handle as sembly B Remove hair pin that retains cable end to traction lever C Slide cable end from traction lever Chassis and Controls Page 6 12 3 Disconnect traction drive cable from traction idler bracket under machine Fig 12 A Loosen jam nuts that secure cable to chassis bracket B Disconnect cable spring from idler bracket 4 Note routing of traction drive cable Remove cable from machine Installation Fig 11 1 Position traction drive cable to machine Line Painter 1200 2 Connect traction drive cable to traction lever on ma chine handle A Slide cable end onto traction lever and secure with hair pin B Secure cable to handle assembly with jam nut C Make sure that cable boot is positioned over end of cable
15. Drain paint tank see Operator s Manual Operate line painter in the flush mode to clean paint tubes 2 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug Paint System Page 5 20 15 Flat washer 16 Manifold block 17 O ring 18 O ring 19 O ring 20 Spool 3 Remove two 2 cotterless pins item 13 that retain lever to shutoff valve Fig 20 4 Slide lever out of manifold block and place to side 5 Pull spool from manifold block Remove and discard o rings from spool Thoroughly clean spool and man ifold block 6 Install new o rings on spool Lightly grease o rings and spool Push spool into manifold block 7 Install lever and secure with two 2 cotterless pins item 13 Line Painter 1200 Paint Shutoff Valve Removal Fig 18 1 Drain paint tank see Operator s Manual Operate line painter in the flush mode to clean paint tubes 2 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug 3 Remove flush tank see Flush Tank Removal in this section 4 Remove inlet and outlet hoses from paint shutoff valve Fig 19 see Quick Disconnect Fitting in the Gen eral Information section 5 Disconnect
16. Drive This page is intentionally blank Line Painter 1200 Chapter 1 TORO Safety Table of Contents SAFETY INSTRUCTIONS aaa 2 Before Operating aaa 2 While Operating aa 2 Maintenance and Service 3 SAFETY AND INSTRUCTION DECALS 4 Line Painter 1200 Page 1 1 Safety Safety Instructions The Line Painter 1200 is designed and tested to offer safe service when operated and maintained properly Although hazard control and accident prevention par tially are dependent upon the design and configuration of the machine these factors are also dependent upon the awareness concern and proper training of the per sonnel involved in the operation transport mainte nance and storage of the machine Improper use or maintenance of the machine can result in injury or Before Operating 1 Read and understand the contents of the Operator s Manual before starting and operating the machine Be come familiar with the controls and know how to stop the machine quickly A replacement Operator s Manual is available on the Internet at www Toro com or by sending the complete model and serial number to The Toro Company Attn Technical Publications 8111 Lyndale Avenue South Bloomington Minnesota 55420 1196 2 Keep all shields safety devices and decals in place If a shield safety device or decal is defective illegible or damaged repair or replace it before o
17. M12 X 1 25 80 10 ft Ib f 108 14 N m Class 8 8 M12 X 1 5 80 10 fb 108414 N m Class 8 8 For steel wheels and non lubricated fasteners Thread Cutting Screws Thread Cutting Screws Zinc Plated Steel Zinc Plated Steel Thread Threads per Inch Size Baseline Torque Type A Type B 1 2 A 1 Type 1 Type 23 or Type F Thread Size Baseline Torque No 6 32 UNC 20 5 inb Co 2 55 No 8 32 UNC 30 5 in Ib 16 7i No No i hes e e omen No 10 24 UNC 38 7 in Ib 1 4 20 UNC 85 15 inb 5 16 18 UNC 110 20 in Ib Hole size material strength material thickness amp finish must be considered when determining specific torque 3 8 16 UNC 200 100 in lb values All torque values are based on non lubricated fasteners Conversion Factors in lb X 11 2985 N cm N cm X 0 08851 in lb ft lb X 1 3558 N m N m X 0 7376 ft Ib Product Records and Maintenance Page 2 6 Line Painter 1200 Chapter 3 TORO Gasoline Engine Table of Contents INTRODUCTION 00 cece eee eee 2 SPEGIFIGATIONS aa ANA ie aS 3 GENERAL INFORMATION 22222 4 Fuel Shut off Valve aaa 4 SERVICE AND REPAIRS sss 5 Cooling System EE EE ee Ee ee 5 Fuel Tank uere cepa b n bs BE SONE 6 Englhlez OE up ELE pian 8 KAWASAKI FJ180V SERVICE MANUAL oO oO Ec e ag S i 6 Line Painter 1200 Page 3 1 Gasoline Engine Introduction This Chap
18. control rod for proper shifting 3 Secure high tension lead to spark plug Traction Drive System o 2 Ta a c e S pe E o D gt 2 Transaxle ANTISEIZE LUBRICANT ANTISEIZE ANTISEIZE LUBRICANT LUBRICANT Figure 4 1 Transaxle assembly 7 Brake return spring 12 Shift lever 2 Flange nut 4 used 8 Carriage screw 4 used 13 Drive pulley 3 Thrust washer 9 Cap screw 14 External snap ring 4 Wheel and tire 10 Lock washer 15 Washer 5 Square key 11 Spacer 16 E ring 6 Spacer Removal Fig 4 1 Park machine on a level surface stop engine and re move key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug 2 Disconnect shift linkage from shift lever on transaxle see Shift Lever and Linkage in this section 3 Disconnect brake cable from transaxle see Brake Cable Removal in the Service and Repairs section of Chapter 6 Chassis 4 Disconnect brake return spring item 7 from brake lever on transaxle 5 Remove traction drive belt from transaxle pulley see Traction Drive Belt Removal in this section Traction Drive System Page 7 6 6 Chock front castor wheel Raise machine so that rear of machine is off the ground Support machine to pre vent it from shifting during transaxle removal 7 Remove rear wheels see Wheel Removal in the Service and Repairs section of Chapter 6 Chassis
19. damaged install a new decal Part numbers for replace ment decals are listed in your Parts Catalog Order re placement decals from your Authorized Toro Distributor Safety Page 1 4 Line Painter 1200 Chapter 2 TORO Product Records and Maintenance Table of Contents o 0 TO PRODUCT RECORDS ama 1 Standard Torque for Dry Zinc Plated and 9 5 MAINTENANCE 2222000002 1 Steel Fasteners Inch Series 4 WIN EQUIVALENTS AND CONVERSIONS 2 Standard Torque for Dry Zinc Plated and 9 E Decimal and Millimeter Equivalents 2 Steel Fasteners Metric Fasteners 5 3 U S to Metric Conversions 2 Other Torque Specifications 6 Mig TORQUE SPECIFICATIONS 3 Conversion Factors aa 6 Fastener Identification 3 Product Records Insert a copy of the Operator s Manual and Parts Cata log for your Line Painter 1200 at the end of this chapter Additionally if any optional equipment or accessories have been installed to your machine insert the Installa tion Instructions Operator s Manuals and Parts Cata logs for those options at the end of this chapter Maintenance Maintenance procedures and recommended service in tervals for the Line Painter 1200 are covered in the Op erator s Manual Refer to that publication when performing regular equipment maintenance Line Painter 1200 Page 2
20. extension spring item 9 from lever item 10 6 Remove hair pin item 11 and pin item 12 that se cure cable to lever 7 Remove two 2 cotterless pins item 13 that retain lever to shutoff valve Fig 20 Remove lever from valve 8 Remove flange nut item 5 cap screw item 14 and flat washer item 15 that secure shutoff valve to tank support Remove valve from machine 9 If needed remove fittings from shutoff valve 10 If required push spool from manifold block Remove and discard o rings Thoroughly clean spool and man ifold block Paint Shutoff Valve Installation Fig 18 1 If spool was removed from manifold block install new o rings on spool Lightly grease o rings and spool Push spool into manifold block 2 f fittings were removed from shutoff valve apply Saf T Lok PTFE Pipe Sealant or equivalent to threads of fittings see Thread Sealant for Paint System Fittings in the General Information section Install fit tings to valve Torque fittings to values identified in Fig 18 3 Position valve to tank support and install cap screw item 14 flat washer item 15 and flange nut item 5 Do not fully tighten nut 4 Position lever to valve and install two 2 cotterless pins item 13 to secure lever to shutoff valve 5 Secure cable to lever with pin item 12 and hair pin item 11 6 Tighten flange nut item 5 to secure shutoff valve to machine Line Painter 1200 Page 5
21. on pres sure regulator Fig 23 see Quick Disconnect Fitting in the General Information section 6 Remove pressure regulator from machine using Fig ure 22 as a guide 7 If necessary remove fittings from pressure regulator Line Painter 1200 Disassembly Fig 24 NOTE Individual components for the pressure regula tor are not available If pressure regulator is disas sembled for cleaning take care not to damage regulator components 1 Remove knob from pressure regulator 2 Carefully press spring pin from regulator housing 3 Remove collar spring and poppet from regulator housing Assembly Fig 24 1 Assemble regulator in the reverse order of disas sembly Make sure that spring pin is centered in housing before installing jam nut and knob to housing Installation Fig 22 1 If fittings were removed from pressure regulator ap ply Saf T Lok PTFE Pipe Sealant or equivalent to threads of fittings see Thread Sealant for Paint System Fittings in the General Information section Install fit tings to regulator Torque fittings to values identified in Fig 22 2 Install regulator to machine using Figure 22 as a guide 3 Install hoses to fittings on pressure regulator Fig 19 see Quick Disconnect Fitting in the General Infor mation section 4 If equipped install pressure gauge to machine 5 Install flush tank see Flush Tank Installation in this section 6 Secure high tension lead to
22. paint flush lever to OFF engine not run ning to prevent paint leakage Quick Disconnect Fittings The Line Painter 1200 uses several quick disconnect fit tings that provide excellent sealing and allow easy dis assembly To remove a hose from a quick disconnect fitting push the release collar in toward the fitting and then pull the hose from the fitting To install a hose into a quick disconnect fitting fully push the hose into the col lar Pull lightly on the hose to make sure it is secured in the fitting If the end of the tubing is scratched deformed or not cut squarely the fitting seal will not be effective and leakage will occur Thread Sealant for Paint System Fittings Many fittings used in the Line Painter 1200 paint system have a sealant patch applied to the fitting threads Ifa fitting is being replaced and a sealant patch is evident on the threads of the new fitting there is no need to apply additional thread sealant before installation If a fitting has been removed however the sealant patch may not allow a leak free seal if the fitting is re installed If a fitting is to be re installed apply Saf T Lok brand Line Painter 1200 Page 5 9 Rev A Figure 1 1 Paint lever in OFF 3 Paint mode 2 Flush mode ES Figure 2 1 Fitting 3 Hose 2 Release collar TPS PTFE Sealant to the fitting threads before installation If an alternate sealant is used make sure that it is compatible w
23. ring Sprocket 18T Spacer Spur gear 35T Spur gear 27T Spur gear 19T Spacer Washer Flange bearing Oil seal Idler shaft Combination gear Washer Neoprene washer Plain washer LH axle Miter gear 12T Retaining ring Spur gear 32T Miter gear 12T Cross shaft RH axle Lock nut Screw Bracket Washer Brake actuating lever Dowel pin 2 used Brake jaw Brake puck spacer Brake puck Brake disc Lower housing NOTE After transaxle has been disassembled and cleaned pack transaxle with 12 to 16 ounces of 4300 Shell Darina D grease before assembly Page 7 9 Traction Drive System o 2 Ta a c e S ped o D gt 2 This page is intentionally blank Traction Drive System Page 7 10 Line Painter 1200
24. spark plug 1 2 PINS Pressure regulator To RH ball valve Knob Collar Spring Poppet Line Painter 1200 Page 5 23 Rev A Figure 23 3 To paint shutoff valve 4 To spray pump Figure 24 5 Spring pin 6 Jam nut 7 Housing Paint System Ball Valve 3 144 to 156 in lb _ _ 16 3 to 17 6 N m 192 to 216 in Ib PP 21 7 to 24 4 N m 84 to 108 in Ib P d 9 5 to 12 2 N m Pad 192 to 216 in Ib 2k 21 7 to 24 4 N m 144 to 156 in Ib 16 3 to 17 6 N m 84 to 108 in Ib 9 5 to 12 2 N m Figure 25 1 Paint tank 9 Straight fitting 17 Tank support 2 Jam nut 10 Hose clamp 18 Elbow fitting 3 Elbow fitting 11 Tee fitting 19 Lever 4 Flat washer 12 O ring 20 Knob 5 Slotted washer 13 Ball valve 21 Screw 6 Rubber washer 14 Elbow fitting 22 Flat washer 7 Outlet port 15 Drain valve bracket 23 Spacer 8 Ball valve bracket 16 Flange screw 5 used 24 Recirculation port Removal Fig 25 1 Drain paint tank and clean the paint system with clean water see Operator s Manual 2 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug 3 Remove flush tank see Flush Water Tank Removal in this section 4 Remove elbow fitting item 3 jam nuts item 2 and washers items 4 and 5 that secure ball val
25. 1 Product Records and Maintenance Decimal and Millimeter Equivalents Equivalents and Conversions Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 03125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1 16 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 9375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 8 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 16 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 034375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625
26. 2 Connect brake cable to brake lever on handle Fig 4 Secure high tension lead to spark plug 6 A Slide cable end onto brake lever and secure with hair pin B Secure cable to handle assembly with jam nut 3 Connect brake cable to brake lever on transaxle Fig 7 A Connect cable spring to brake lever B Position cable to chassis bracket C Tighten cable jam nuts enough to prevent cable spring hook from coming off transaxle brake lever When properly adjusted the cable spring should not be stretched Figure 7 T 1 Brake cable spring 3 Cable jam nut D Make sure that cable boot is positioned over end 2 Brake lever of cable ke Sa og Ne 0 co 9 Line Painter 1200 Page 6 9 Chassis and Controls Castor Release Cable Figure 8 4 Cap screw 5 Flat washer 1 Castor release lever 2 Rubber bumper 3 Traction lever Removal Fig 8 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug 2 Disconnect castor release cable from castor release lever on machine handle A Loosen jam nut that secures cable to handle as sembly B Remove hair pin that retains cable end to castor release lever C Slide cable end from castor release lever 3 Disconnect castor release cable from castor release detent under f
27. 2 If engine is to be disassembled it may be easier to drain oil from engine before removing engine from ma chine see Operator s Manual 3 Close fuel shut off valve Disconnect fuel hose from carburetor inlet Gasoline Engine Page 3 8 4 Remove fuel tank from machine see Fuel Tank Re moval in this section 5 If machine is equipped with a hour meter remove hour meter pickup wire from spark plug lead on engine Position pickup wire away from engine 6 Disconnect stop switch wire from engine Fig 6 Make sure that ground wire is removed from fuel tank bracket item 14 Line Painter 1200 7 On the underside of the machine frame Fig 7 A Loosen flange nuts that retain two 2 belt guides to frame Position belt guides away from engine pulley B Loosen idler tension on pump drive belt lower and transmission drive bolt upper and remove belts from engine pulley C Remove four 4 screws that secure engine to machine 8 Lift the engine from the frame 9 If necessary remove cap screw that secures pulley to engine crankshaft Slide pulley from crankshaft Installation Fig 5 1 Position machine on a level surface 2 Make sure that all parts removed from the engine during maintenance or rebuilding are properly installed to the engine 3 If pulley was removed from engine apply antisieze lubricant to engine crankshaft Slide pulley onto crank shaft making sure to align pulley key with cranks
28. Apply Saf T Lok PTFE Pipe Sealant or equivalent to threads of all removed fittings see Thread Sealant for Paint System Fittings in the General Information sec tion Install fittings to ball valves as follows A Tighten recirculation port item 24 so that clear ance between port neck and top of bracket is from 0 000 flush to 030 0 to 8 mm Fig 28 B Tighten outlet port item 7 so that clearance be tween bottom of hex and top of bracket is from 0 000 flush to 030 0 to 8 mm Fig 28 C Torque remaining fittings to value identified in Fig 25 4 Place new rubber washers item 6 on ball valve ports Position ball valve assembly to machine 5 Install two 2 flange screws item 16 that secure ball valve assembly to tank support but do not fully tighten 6 Install washers items 4 and 5 jam nuts item 2 and elbow fitting item 3 that secure ball valve fittings to paint tank Tighten jam nuts Torque elbow fitting from 144 to 156 in lb 16 3 to 17 6 N m 7 Tighten two 2 flange screws item 16 8 Install hoses to fittings on ball valves Fig 26 see Quick Disconnect Fitting in the General Information sec tion 9 Install knob item 19 to lever Line Painter 1200 Page 5 25 Rev A 10 Install flush tank see Flush Water Tank Installation in this section 11 Secure high tension lead to spark plug Figure 26 3 Lever paint position Tos
29. E If fuel is spilled do not start engine Move the ma chine away from the area of spillage and allow the gasoline vapors to dissipate Properly dispose of any spilled fuel 7 While operating the Line Painter 1200 may exceed noise levels of 85dB A at the operator position Hearing protection is recommended for prolonged exposure to reduce the potential of permanent hearing damage 8 Before leaving the operator s position of the Line Painter 1200 A Release paint control lever to stop the paint op eration B Ensure that vehicle traction lever is in neutral ap ply parking brake stop engine and remove key from ignition switch 9 Use only latex base paint in the Line Painter 1200 Do not use oil based paint Line Painter 1200 Maintenance and Service 1 Before servicing or making adjustments position machine on a level surface and apply parking brake to prevent machine from moving 2 Disconnect the spark plug wire from the spark plug and position the wire away from the spark plug to ensure that the engine will not start accidentally 3 Make sure machine is in safe operating condition by keeping all nuts bolts and screws tight 4 Never store the machine or fuel container inside where there is an open flame such as near a water heat er or furnace 5 Make sure all paint system line connectors are tight and all paint system hoses and lines are in good condi tion before applying pressure to the paint system
30. Gal e 1 2 GAL 18 MESH BASKET ECHANICALLY LINKED BALL VALVES SHOWN IN FLUSH POSITION ADJUSTABLE REGULATOR Lx I er yj PRESSURE A GAUGE 0 60 PSI OPTIONAL Y 4 GPM 5 CHAMBER DIAPHRAGM PUMP WITH ADJUSTABLE RELIEF VALVE 40 MESH FILTER OPTIONAL HAND WAND KIT QUICK BALL HAND WAND DISCONNECT VALVE EE rd POSITION MECHANICAL ACTUATED SPOOL VALVE PAINT POSITION WW Di a l NOZZLE ASM WITH 10 PSI DIAPHRAGM NO DRIP CHECK VALVE Line Painter 1200 Flush Circuit Working Pressure Return Suction Flow Paint System Page 5 6 Line Painter 1200 Flush Circuit The Line Painter 1200 paint circuit uses a positive dis placement diaphragm pump to move fluid water from the flush water tank through the spray system The spray pump is a self priming diaphragm pump that has a dry crankcase When the pump is rotated the downward stroke of the pump s diaphragm creates suction to allow fluid water to be drawn from the flush tank to the pump via hoses a one way check valve a ball valve in the flush posi tion and a 40 mesh screen filter Once to the pump the fluid water is pushed by the up ward stroke of the pump s diaphragm to the pressure side of the spray system through hoses control valves and the spray nozzle Maximum pressure in th
31. IRS sss 6 Wheels aud DEE RR Rr iw DER P a eR 6 Brake Gable is EERS EE NANG Ng ep bar ud 8 Castor Release Cable 10 Traction Drive Cable 0 0000 ee 12 Paint Control Cable sees 14 Front Castor Fork 00 00 cee eee eee 16 O Sa og Ne 0 co 9 Line Painter 1200 Page 6 1 Chassis and Controls Specifications Item Description Tire Pressure Front Castor Tire 18 to 20 PSI 1 2 to 1 4 Bar Rear Tire 12 to 15 PSI 0 8 to 1 0 Bar Chassis and Controls Page 6 2 Line Painter 1200 Adjustments Traction Drive Cable 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug 2 Make sure that traction lever on handle is released 3 Adjust location of traction cable jam nuts so that trac tion cable spring is stretched 120 to 250 3 0 to 6 4 mm from it s relaxed state 4 Make sure that jam nuts are fully tightened and that boot is positioned on end of traction cable 5 Secure high tension lead to spark plug Figure 1 1 Traction drive cable 4 Cable spring 2 Idler bracket 5 Cable boot 3 Jam nut O 5o og oc 20 co o Line Painter 1200 Page 6 3 Chassis and Controls Front Castor Fork Figure 2 1 Front castor wheel 2 Socket head screw 2 used
32. TE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite 3 4 16 UNF 115 4 15 165 4 25 224 34 7 8 9 UNC 140 20 225 25 305 34 y io o n vlaloe N IR IN j o o gt gt jo lo 7 8 14 UNF 155 25 260 30 353 41 ep EIER soe sa EE aar ss ese s reuke 16x2 i622 coe oo Oes Er ae ms sae ss mse rs me e FEE Na x A Sems screw is a self tapping screw equipped with a captive washer NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material strength length of thread engagement etc Product Records and Maintenance Page 2 4 NOTE The nominal torque values listed above for Grade 5 and 8 fasteners are based on 7596 of the mini mum proof load specified in SAE J429 The tolerance is approximately 1096 of the nominal torque value Thin height nuts include jam nuts Line Painter 1200 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Regular Height Nuts Class 8 or Stronger Nuts Thread Size M5 X 0 8 57 6 in lb 96 10 in Ib Class 8 8 Bolts Screws and Studs with Class 10 9 Bolts Screws and Studs with Regular H
33. TION Paint Circuit Flush Circuit TROUBLESHOOTING GENERAL INFORMATION Paint Flush Lever Quick Disconnect Fittings Thread Sealant for Paint System Fittings ADJUSTMENTS Spray Pump Relief Valve Adjustment Line Painter 1200 Chapter 5 Paint System 2 SERVICE AND REPAIRS seus 12 3 Paint Tank pia pach haka Gees pamana ANA 12 4 Tank Support 00 EG ee eee eee 14 4 Flush Water Tank cee eee eee 16 6 Check Valve Service cece eee 18 8 Paint Shutoff Valve aaa 20 9 Pressure Regulator eee eeee 22 9 Ball Valve i oibus reiten 24 9 Spray Pump Drive Belt 00005 26 9 Spray PUMP sc 2008 e Ree e EAM 28 10 Spray Pump Service ss Se see 30 10 Spray Head 2 S Eoo REG NA By de 32 Page 5 1 Paint System Specifications Item Description Pump Pump Capacity Relief Pressure Diaphragm Pump with 5 Chambers 4 GPM 15 1 LPM 65 PSI 4 5 Bar Paint Tank Capacity 12 Gallons 45 4 Liters Water Flush Tank Capacity 2 5 Gallons 9 5 Liters Paint System Page 5 2 Line Painter 1200 Paint Schematic PAINT 2 GAL 18 MESH BASK WATER 2 1 2 GAL ECHANICALLY LINKED BALL VALVES SHOWN IN PAINT POSITION ADJUSTABLE REGULATOR 40 MESH FILTER p 7 PRESSURE GAUGE 0 60 PSI NVC OPTIONAL
34. TORO Preface The purpose of this publication is to provide the service technician with information for troubleshooting testing and repair of major systems and components on the Line Painter 1200 REFER TO THE OPERATOR S MANUALS FOR OP ERATING MAINTENANCE AND ADJUSTMENT INSTRUCTIONS Space is provided in Chapter 2 of this book to insert the Operator s Manuals and Parts Cata logs for your machine Replacement Operator s Manu als are available on the internet at www toro com or by sending complete Model and Serial Number to The Toro Company Attn Technical Publications 8111 Lyndale Avenue South Minneapolis MN 55420 The Toro Company reserves the right to change product specifications or this publication without notice Part No 05144SL Rev A Service Manual Line Painter 1200 This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE A NOTE will give general information about the correct operation maintenance service testing or re pair of the machine IMPORTANT The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 2005 2007 This page is intentionally blank Line Painter 1200 Table Of Contents Chapter 1 Safety S
35. afety Instructions a 1 2 Safety and Instruction Decals 1 4 Chapter 2 Product Records and Maintenance Product Records a 2 1 Maintenance cee eee eee 2 1 Equivalents and Conversions 2 2 Torque Specifications 2 3 Chapter 3 Gasoline Engine Introduction a cee eee eens 3 2 Specifications sesanan 3 3 General Information usus 3 4 Service and Repairs aa 3 5 KAWASAKI FJ180V SERVICE MANUAL Chapter 4 Electrical System Electrical Schematic aa 4 2 Special Tools 00 cece eee eee eee 4 3 Troubleshooting aaa 4 4 Component Testing 000e eee eee 4 5 Line Painter 1200 Chapter 5 Paint System Specifications ie EE EE EE RE eee Paint Schematic a Circuit Operation EE EE cee eee Troubleshooting EE EE EE eee eee General Information ie aaa Adjustments 0 c eee ee eee eee Service and Repairs ssssuu Chapter 6 Chassis and Controls Specifications 0 EE EE ee eee Adjustments 0 0 c eee eee eee ees Service and Repairs aa Chapter 7 Traction Drive System Service and Repairs a DANA MODEL 4360 TEARDOWN AND ASSEMBLY INSTRUCTIONS Product Records and Maintenance Gasoline Engine Electrical ke So og Ne 0 co 9 Traction
36. e kit If wobbler plate diaphragm is damaged replace pump 3 Inspect pump endbell and drive housing bearings Bearings should rotate freely with no evidence of wear or roughness Bearing seals should be intact and show no signs of lubricant leakage Assembly Fig 32 1 If bearing was removed from pump endbell install new bearing into endbell IMPORTANT When assembling pump make sure to lower pump head onto check valve kit to keep out let check valves in position 2 Place check valve kit onto wobbler plate diaphragm assembly Fig 35 Position outlet check valves to top of check valve kit 3 Lower pump head onto valve kit aligning diagonal line made during disassembly Fig 33 4 Install five 5 shorter 1 5 38 1 mm length screws with lock washers and flat washers to secure pump head to wobbler plate diaphragm assembly Tighten screws in a crossing pattern and in three equal steps to a final torque from 25 to 30 in lb 2 8 to 3 4 N m DO NOT over tighten screws 5 Position gasket and end bell to pump assembly aligning diagonal line made during disassembly Fig 33 6 Install five 5 longer 2 50 8 mm length screws with flat washers to secure pump assembly to endbell Tighten screws in a crossing pattern and in three equal steps to a final torque from 25 to 30 in Ib 2 8 to 3 4 N m DO NOT over tighten screws 7 If pump drive housing was disassembled A Press bearings onto drive shaft Mak
37. e spray head to allow the flush tank to be emptied faster 2 Operate line painter in the flush mode until the flush tank is empty 3 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Remove high tension lead from the spark plug N and position the lead away from the spark plug Figure 12 4 Tip tank support to gain access to flush tank see T Flushta k 3 Tank support rod 2 Extension spring Tank Support in this section Paint System Page 5 16 Line Painter 1200 5 Unhook extension spring from hole in tank support Fig 12 Remove spring and tank support rod from ma chine 6 Remove flush tank outlet tube from elbow fitting on bottom of ball valve Fig 13 and 14 see Quick Discon nect Fitting in the General Information section 7 Remove flush tank with outlet tube attached from machine 8 If necessary remove outlet tube and check valve from flush tank Fig 14 Installation Fig 11 1 If removed attach outlet tube and check valve to flush tank Fig 14 Make sure that check valve is installed to allow free flow from flush water tank Fig 15 2 Position flush tank to machine Connect flush valve outlet tube to elbow fitting on bottom of ball valve Fig 13 and 14 See Quick Disconnect Fitting in the General Information section 3 Secure flush tank to machine with tank support rod and extension spring 4 Return tank suppor
38. e sure bear ings contact drive shaft shoulder Line Painter 1200 Page 5 31 B Slide drive shaft and bearings into housing C Install retaining rings into pump drive housing grooves 8 Apply antiseize lubricant to drive shaft Position pump gasket to pump housing Slide spray pump onto drive shaft Align tab on pump with slot on pump drive housing 9 Secure spray pump to pump drive housing with two 2 socket head screws and lock washers Torque sock et head screws from 22 to 28 in lb 2 5 to 3 2 N m DO NOT over tighten screws 10 If fittings and or filter were removed from pump as sembly install new o ring slide fitting or filter into hous ing and secure with retainer 22 to 28 in Ib 2 5 to 3 2 N m 22 to 28 in Ib B H 8 2 5 to 3 2 N m A Figure 34 1 Spray pump 5 Socket head screw 2 Pump gasket 6 Retaining ring 3 Pump drive housing 7 Drive shaft 4 Lock washer 8 Ball bearing Figure 35 Wobbler plate diaphragm assembly Check valve kit Outlet check valve 5 used O ring ROPI Paint System Spray Head 168 to 216 in Ib p 19 to 24 4 N m Saf T Lok PTFE Pipe Sealant t5 Saf T Lok PTFE Pipe Sealant 144 to 156 in Ib 16 3 to 17 6 N m Figure 36 1 Hose 8 Shield 15 Clamp bracket 2 Hose clamp 9 Nozzle bracket 16 Spray arm 3 Barb fitting 10 Diaphragm nozzle 17 Stop 4 Nozzle tube 11 Spray nozzle 18 Jam nut 5 Wing nut 12 Seat gaske
39. e system is limited by an adjustable relief valve located in the dia phragm pump Flow in excess of the adjustable pressure regulator set ting is directed back to the flush water suction line via a ball valve in the flush position Line Painter 1200 Page 5 7 Flow through the flush circuit is used to dilute and re move paint from the ball valves screen filter spray pump regulator spool valve spray nozzle and all hoses A one way check valve is positioned between the flush water tank and the ball valve see schematic This check valve prevents paint from entering the flush wa ter tank when the paint flush lever is moved from the paint position to the flush position and while the machine is operated in the flush mode NOTE If the flush system is not cleaned after use di luted paint may cause check valve and associated hoses to become blocked If the check valve is stuck open paint may enter the flush water tank when the paint flush lever is moved from the paint position to the flush position If the check valve is stuck closed the flush system may not operate Paint System Troubleshooting Problem Possible Cause Spray system leaks fluid Spray pressure is low Fitting s or hose s are loose or damaged O ring s or seal s are missing or damaged Suction line is restricted Filter screen is plugged Pressure regulator is damaged or incorrectly adjusted Spray nozzle is worn or da
40. eight Nuts Class 10 or Stronger Nuts 644 68 N cm 78 8 in Ib 881 90 N cm 1085 113 N cm 133 14 in lb 1503 158 N cm M6 X 1 0 M8 X 1 25 M10X 1 5 19 2 ft Ib 38 4 ft lb M12 X 1 75 M16 X 2 0 M20 X 2 5 NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material strength length of thread engagement etc 66 7 ft lb 166 17 ft lb 325 33 ft lb NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite Line Painter 1200 26 3 N m 90 10 N m 93 10 ft lb 126 14 N m 225 23 N m 229 23 ft lb 310 31 N m 450 46 ft Ib 610 62 N m Page 2 5 28 3 fb 38 4 N m NOTE The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 10 of the nominal torque value Product Records and Maintenance Product Records 5 c o c 7 S o ge ed o Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Grade 5 1 2 20 UNF 80 10 ft lb 108 14 N m 5 16 18 UNC 215 4 35in Ib 145 20 inb Grade 5 3 8 16 UNC 35 10 ft lb 18 3 ft lb
41. g on the plunger not to damage the check valve or to allow contaminates into the valve B If the check valve is stuck due to dried paint soak check valve in water to clean If soaking in water will not free valve check valve replacement is neces sary 4 Install check valve to tubes see Quick Disconnect Fitting in the General Information section Fig 16 Make sure that check valve is installed to allow free flow from flush water tank Fig 17 5 Install flush tank see Flush Tank Installation in this section Figure 16 1 Flush tank 3 Check valve 2 Outlet tube from tank 4 Outlet tube to valve LOW DIRECT o Figure 17 1 Outlet tube from tank 2 Tube to ball valve Paint System Page 5 18 Line Painter 1200 This page is intentionally blank Line Painter 1200 Page 5 19 Paint System Paint Shutoff Valve PAINT SHUTOFF VALVE 16 192 to 216 in Ib 21 7 to 24 4 N m 6 7 a 144 to 156 in Ib 16 3 to 17 6 N m Figure 18 1 Paint tank 8 Plug 2 Tank support 9 Extension spring 3 Elbow fitting 10 Lever 4 Paint shutoff valve 11 Hair pin 5 Flange nut 12 Pin 6 Straight fitting 13 Cotterless pin 7 Tee fitting 14 Cap screw Paint Shutoff Valve Spool Fig 18 The spool can be removed from the paint shutoff valve without removing the complete valve from the machine using the following procedure 1
42. ground wire from bracket 7 If fuel in tank was contaminated remove and clean carburetor see Kawasaki FJ180V Service Manual at the end of this chapter Fuel Tank Installation Fig 4 1 If carburetor was removed from engine for cleaning install carburetor see Kawasaki FJ180V Service Manu al at the end of this chapter 2 Install fuel tank to frame using Figure 4 as a guide If ground wire was removed from fuel tank bracket item 14 secure ground wire to bracket with screw 3 Connect fuel hose to carburetor inlet Make sure that fuel hoses are secured with hose clamps 4 Attach high tension lead to the spark plug 5 Fill fuel tank see Operator s Manual Gasoline Engine oO oO ER e ag aT O Engine 250 to 450 in Ib 28 to 51 N m Ce 20 to 30 ft Ib 27 to 41 N m 50 to 60 ft lb 68 to 81 N m Loctite 242 Figure 5 1 Engine 8 Frame 14 Hose clamp 4 used 2 Oil drain valve 9 Fuel tank support 15 Fuel hose 3 O ring 10 Washer head screw 2 used 16 Fuel shut off valve 4 Drain extension 11 Fuel tank cap 17 Fuel hose 5 Screw 6 used 12 Fuel tank 18 Engine pulley 6 Washer head screw 2 used 13 Fuel tank bracket 19 Cap screw 7 Nut 2 used Removal Fig 5 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug
43. haft slot 4 Apply Loctite 242 or equivalent to threads of cap screw item 19 Secure pulley to crankshaft with cap screw Torque cap screw from 50 to 60 ft lb 68 to 81 N m 5 Position engine on the frame 6 Align holes in frame with engine mounting holes Se cure engine to frame with four 4 screws Torque screws from 250 to 450 in Ib 28 to 51 N m 7 Onthe underside of the machine frame Fig 7 A Install transmission drive belt upper and pump drive belt lower onto engine pulley Make sure that belts are correctly routed at idler pulleys B Position two 2 belt guides to allow from 060 to 130 1 5 to 3 3 mm clearance when the traction upper belt is tensioned by the idler pulley When properly positioned tighten flange nuts to secure belt guides to frame Line Painter 1200 Page 3 9 8 Install fuel tank to machine see Fuel Tank Installa tion in this section 9 If machine is equipped with a hour meter install hour meter pickup wire to spark plug lead on engine 10 Connect stop switch wire to engine Secure ground wire to fuel tank bracket item 14 with screw 11 Check and adjust engine oil level as needed See Checking Engine Oil Level 12 Attach high tension lead to the spark plug 13 Make sure that fuel hose is secured to carburetor in let Open fuel shut off valve Figure 6 1 Fuel shut off valve 2 Stop switch wire Figure 7 1 Flange nut 2 Belt guide 3
44. ine see Spray Pump Drive Belt Installation in the Service and Repairs section of Chapter 5 Paint System 5 Check traction drive belt cable adjustment see Trac tion Drive Cable in the Adjustments section of Chapter Figure 2 i 1 Traction drive belt 3 Idler pulley classi 2 Idler bracket 4 Bracket belt guide 6 Secure high tension lead to spark plug o 2 GE c2 o9 sr o0 hm Line Painter 1200 Page 7 3 Traction Drive System Shift Lever and Linkage Note Console shown SE Nd ibis from handle 5 for clarity Figure 3 1 Handle 6 Bushing 11 Control rod 2 Console 7 Hair pin 12 Bell crank 3 Knob 8 Clevis pin 13 Pivot shaft 4 Nylon washer 9 Shift lever on transaxle 14 Washer head screw 5 Console shift lever 10 Shift link 15 Rod fitting Traction Drive System Page 7 4 Line Painter 1200 Disassembly Fig 3 1 Park machine on a level surface stop engine apply parking brake and remove key from the ignition switch Remove high tension lead from the spark plug and posi tion the lead away from the spark plug 2 Disassemble shift linkage components as needed using Figure 3 as a guide Line Painter 1200 Page 7 5 Assembly Fig 3 1 Assemble shift linkage components using Figure 3 as a guide 2 After assembly of shift linkage components make sure that console shift lever movement allows correct transaxle shifting If necessary adjust rod fitting item 15 location on
45. ing screen 3 Cooling fins 3 If necessary remove engine cover rotating screen 2 Blower housing and blower housing from engine Fig 3 Clean blower housing and engine cooling fins of dirt and debris IMPORTANT Never operate engine without the blower housing installed Overheating and engine damage will result 4 Make sure blower housing rotating screen and en gine cover are reinstalled to the engine if removed 5 Attach high tension lead to the spark plug Figure 3 1 Rewind starter 3 Rotating screen 2 Engine cover 4 Blower housing Line Painter 1200 Page 3 5 Gasoline Engine Fuel Tank L 4 La P1 K w 7a Figure 4 1 Fuel tank 6 Fuel hose 11 Frame 2 Fuel tank cap 7 Engine 12 Fuel tank support 3 Hose clamp 4 used 8 Screw 2 used 13 Washer head screw 2 used 4 Fuel hose 9 Washer head screw 2 used 14 Fuel tank bracket 5 Fuel shut off valve 10 Nut 2 used Gasoline Engine Page 3 6 Line Painter 1200 Because gasoline is highly flammable use cau tion when storing or handling it Do not smoke while filling the fuel tank Do not fill fuel tank while engine is running hot or when machine is in an enclosed area Always fill fuel tank outside and wipe up any spilled fuel before starting the engine Store fuel in a clean safety approved container and keep cap in place Use gasoline for the engine only not for any other purpose Check Fuel Lines and Connection
46. inuity check On Off Switch The on off switch is used to shut the engine off When the on off switch is in the off position the engine arma ture is grounded to prevent the engine from running This switch is located handle panel Fig 3 Testing In the OFF position there should be continuity between the two switch terminals In the RUN position there should not be continuity between the two switch termi nals Figure 3 1 On Off switch Electrical System Figure 4 Line Painter 1200 Page 4 5 Electrical System Hourmeter Optional The optional hourmeter available for the Line Painter 1200 uses an inductive pickup wire connected to the spark plug wire to sense when the engine is running The hourmeter should increase 1 10 of an hour every six 6 minutes of engine running time The hourmeter uses its own internal battery for opera tion The hourmeter battery is not replaceable NOTE The hourmeter display is programmed to flash service reminders initially at 50 hours and then every 100 hours thereafter The display will flash for three Figure 5 hours before and three hours after these running times Regardless of these service reminders follow the main tenance intervals identified in the Line Painter 1200 Op erator s Manual Electrical System Page 4 6 Line Painter 1200 TORO Table of Contents SPECIFICATIONS PAINT SCHEMATIC CIRCUIT OPERA
47. ith nylon and polypropylene mate rials Paint System Adjustments Spray Pump Relief Valve Adjustment The spray pump used on the Line Painter 1200 is equipped with an adjustable relief valve Fig 3 Adjust ment of the relief valve is made with a socket head screw on the top of the pump The end of the socket head screw should be flush with the relief valve housing for correct relief valve adjustment Figure 3 1 Spray pump 2 Socket head screw Paint System Page 5 10 Line Painter 1200 This page is intentionally blank Line Painter 1200 Page 5 11 Paint System Service and Repairs Paint Tank 144 to 156 in lb ym 6 16 3 to 17 6 N m D 192 to 216 in b 7 21 7 to 24 4 N m 192 to 216 in Ib 21 7 to 24 4 N m 15 Valve bracket 16 Flange head screw 17 Flange head screw 4 used 18 Pump assembly 19 Flush tank 20 Slotted washer Figure 4 1 Painttank 8 Rubber washer 2 Nut 9 Outlet port 3 Tank support 10 Ball valve 4 Flat washer 11 Recirculation port 5 Jamnut 12 O ring 6 Elbow fitting 13 Drain valve 7 Tank clamp 2 used 14 Elbow fitting Removal Fig 4 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug 2 Drain paint tank see Operator s Manual Remove tank lid and strainer Paint System Page
48. maged Check valve in diaphragm nozzle is stuck or plugged Engine speed is low Pressure relief valve in spray pump is stuck Pump drive belt is slipping Spray pump is faulty No spray output from nozzle No spray output from nozzle in the flush mode Nozzle leaks when paint valve is closed Paint is being pumped into the flush tank Paint System Paint tank is empty Paint Flush lever is in the off position Hose s are pinched or kinked Dried paint in system Filter screen is plugged Spray nozzle is clogged or damaged Check valve in diaphragm nozzle is stuck or plugged Paint shutoff valve is faulty Pump drive belt is slipping damaged or broken Spray pump is faulty Flush tank is empty Check valve in flush tank outlet tube is stuck closed Check valve diaphragm in diaphragm nozzle body is leaking or damaged Paint shutoff valve is not seating Paint control cable is not adjusted correctly see Paint Control Cable in the Service and Repairs section of Chapter 6 Chassis and Controls Check valve in flush tank outlet tube is stuck open Page 5 8 Line Painter 1200 General Information Paint Flush Lever To prevent paint system pressure spikes the paint flush lever should normally be in either the paint mode or the flush mode It is recommended to use the OFF position only when the engine is not running If the paint filter is to be cleaned and paint is in the paint tank turn the
49. nsion lead to spark plug Line Painter 1200 This page is intentionally blank Line Painter 1200 Page 5 27 Paint System Spray Pump VE Figure 30 1 Tank support 6 Flat washer 11 Chassis 2 Flange head screw 4 used 7 Cap screw 12 Cap screw 3 used 3 Spray pump assembly 8 Lock washer 13 Flush tank 4 Flange nut 3 used 9 Set screw 14 Paint tank 5 Pulley 10 Square key Removal Fig 30 1 Drain paint tank see Operator s Manual 2 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug Paint System Page 5 28 3 Remove spray pump drive belt see Spray Pump Drive Belt Removal in this section 4 Loosen two 2 set screws and then remove cap screw item 7 lock washer item 8 and flat washer item 6 that secure pulley to pump shaft Slide pulley from pump shaft Locate and retrieve square key item 10 Line Painter 1200 5 Tip tank support to gain access to spray pump see Tank Support in this section 6 Disconnect suction and pressure hoses from spray pump fittings Fig 31 7 Remove three 3 flange nuts item 4 and cap screws item 12 that secure spray pump to chassis 8 Lift spray pump assembly from machine Installation Fig 30 1 Position spray pump to machine chassis Secure pump to chassis with three 3 flange nut
50. nt 4 Note routing of paint control cable Remove cable control lever from machine C Slide cable end from paint control lever Chassis and Controls Page 6 14 Line Painter 1200 Installation Fig 13 1 Position paint control cable to machine 2 Connect paint control cable to paint control lever on machine handle A Slide cable end onto paint control lever and se cure with hair pin B Secure cable to handle assembly with jam nut C Make sure that cable boot is positioned over end of cable 3 Connect paint control cable to paint shutoff valve Figs 14 A Secure cable clevis to shutoff valve lever with cle vis pin and hair pin B Position shutoff valve lever to shutoff valve and secure with two 2 cotterless pins C Position cable to chassis bracket D Tighten cable jam nuts to allow slight cable free play Verify that operator control lever has E Make sure that cable boot is positioned over end of cable 4 After cable installation verify that operator paint con trol lever has from 050 to 100 1 3 to 2 5 mm freeplay Readjust cable if necessary 5 Secure high tension lead to spark plug Line Painter 1200 Page 6 15 Paint control cable Figure 14 3 Paint shutoff valve Paint shutoff valve lever 4 Cable boot Pivot cotterless pin Figure 15 2 Spool cotterless pin Chassis and Controls ke So ae Ne 0 co 9 Front Castor Fork Figure 16 1
51. o gt 4 GPM 5 CHAMBER DIAPHRAGM PUMP WITH ADJUSTABLE RELIEF VALVE OPTIONAL HAND WAND KIT QUICK HAND WAND i DISCONNECT OM MECHANICAL ACTUATED SPOOL VALVE WW OFF POSITION NG NOZZLE ASM WITH 10 PSI DIAPHRAGM NO DRIP CHECK VALVE Line Painter 1200 Hydraulic Schematic Line Painter 1200 Page 5 3 Paint System Circuit Operation PAINT WATER 2 GAL e Ife GAL 18 MESH BASKET A ECHANICALLY LINKED BALL VALVES pa SHOWN IN PAINT POSITION ADJUSTABLE REGULATOR 40 MESH FILTER PRESSURE GAUGE 0 60 PSI OPTIONAL GPM 5 CHAMBER DIAPHRAGM PUMP WITH ADJUSTABLE RELIEF VALVE OPTIONAL HAND WAND KIT QUICK HAND WAND DISCONNECT Ow Y MECHANICAL ACTUATED SPOOL VALVE PAINT POSITION NOZZLE ASM WITH 10 PSI DIAPHRAGM NO DRIP a a CHECK VALVE Line Painter 1200 Paint Circuit Working Pressure Return Agitation Suction Flow Paint System Page 5 4 Line Painter 1200 Paint Circuit The Line Painter 1200 paint circuit uses a positive dis placement diaphragm pump to move paint from the paint tank to the spray nozzle The spray pump is a self priming diaphragm pump that has a dry c
52. o machine 6 Install elbow fitting item 6 and torque from 144 to 156 in Ib 16 3 to 17 6 N m Install agitation tube to el bow fitting Fig 5 see Quick Disconnect Fitting in the General Information section 7 If removed install tank lid flange using Figure 6 as a guide Torque screws from 10 to 12 inb 1 1 to 1 4 N m 8 Install high tension lead to spark plug when service is complete 1 Drain valve 2 Elbow fitting 1 Paint tank 2 O ring 3 Lid flange Line Painter 1200 Page 5 13 Figure 5 3 Jam nut 4 Agitation tube 10 to 12 in Ib 1 1 to 1 4 N m Figure 6 4 Strainer 5 Lid 6 Screw 8 used Paint System Tank Support Figure 7 1 Handle assembly 3 Chassis 5 Tank support 2 Flange head screw 4 used 4 Flush tank 6 Paint tank Paint System Page 5 14 Line Painter 1200 To ease service of paint components attached to the tank support the tank support and handle can be tipped back using the following procedure 1 Drain paint tank see Operator s Manual NOTE The nozzle can be removed from the spray head to allow the flush tank to be emptied faster 2 Clean paint system hoses by operating line painter in the flush mode until the flush tank is empty 3 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug 4 Rem
53. orque Specifications Recommended fastener torque values are listed in the following tables For critical applications as determined by Toro either the recommended torque or a torque that is unique to the application is clearly identified and spe cified in this Service Manual These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Ser vice Manual The following factors shall be considered when applying torque cleanliness of the fastener use of a thread sealant e g Loctite degree of lubrication on the fastener presence of a prevailing torque feature e g Nylock nut hardness of the surface underneath the fastener s head or similar condition which affects the installation Fastener Identification Grade 1 Grade 5 Inch Series Bolts and Screws Figure 1 Line Painter 1200 Page 2 3 As noted in the following tables torque values should be reduced by 2596 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be determined based on the aluminum or brass material strength fastener size length of thread en gagement etc The standard method of verifying torque shall be per formed by marking a line on the fastener head or nut and mating part then back off fastene
54. ousing as sembly Fig 34 A Remove retaining rings from grooves in pump drive housing B Slide drive shaft and bearings from housing C Press bearings from drive shaft 3 Use a marker to make a diagonal line across the pump head wobbler plate diaphragm assembly and pump endbell for assembly purposes Fig 33 4 Loosen and remove ten 10 screws that retain pump head to endbell Locate and retrieve lock washers and flat washers Paint System Page 5 30 5 Carefully separate pump head from pump endbell Remove and discard gasket Separate wobbler plate di aphragm assembly check valve kit and pump head 6 If necessary remove bearing from pump endbell 7 If necessary remove filter item 11 from pump head by sliding retainer and pulling filter from pump head Re move and discard o ring item 8 DIAGONAL Figure 33 Line Painter 1200 8 If necessary remove fittings in filter item 7 and or pump head item 16 by sliding retainer and pulling fit ting from housing Remove and discard o rings item 8 Inspection 1 If paint has dried on internal pump parts compo nents or complete pump replacement will most likely be required IMPORTANT Do not attempt to clean internal pump components with solvents as component damage will occur 2 Inspect check valve kit and diaphragm assembly for deformation erosion of sealing areas or debris If indi vidual valves are damaged replace check valv
55. ove the hairpin and flat washer that secure the shift rod to the shift bellcrank at the rear of the machine Fig 8 5 Disconnect shift rod from shift bellcrank Take care to not change location of fitting on shift rod 6 Loosen the rear two flange head screws that fasten tank support to chassis Fig 9 7 While supporting handle and tank support in the up right position remove the front two 2 flange head screws that fasten tank support to chassis Fig 9 8 Carefully tilt handle and tank support back to allow access to tank support components Fig 10 9 After repairs are completed raise handle and tank support Install front two 2 flange head screws to fas ten tank support to chassis Tighten all four 4 flange head screws to secure tank support to machine 10 Slide shift rod fitting onto shift bellcrank and secure with flat washer and hairpin 1 Shift rod 4 Flat washer 2 Shift bellcrank 5 Fitting 3 Hairpin Figure 9 1 Tank support 3 Front flange screw 2 Rear flange screw Figure 10 Line Painter 1200 Page 5 15 Paint System Flush Water Tank Figure 11 1 Paint tank 6 Stud 11 Elbow fitting 2 Tank support 7 Flush tank 12 Clamp 3 Cap 8 Extension spring 13 Bushing 4 Cap insert 9 Tank support rod 14 Flange head screw 4 used 5 Gasket 10 Spray pump assembly Removal Fig 11 1 Drain paint tank see Operator s Manual NOTE The nozzle can be removed from th
56. p of castor fork Secure castor fork to ma chine with flange head screw item 13 5 Install castor wheel to castor fork see Wheel Instal lation in this section Line Painter 1200 Page 6 17 6 Carefully lower machine to ground 7 Lubricate grease fitting for castor fork 8 Secure high tension lead to spark plug 9 Release castor release lever on handle to engage castor detent 10 Operate machine to make sure it follows a straight line If machine does not track correctly adjust front cas tor fork see Front Castor Fork in the Adjustments sec tion Chassis and Controls O Sa og oc 20 co 9 This page is intentionally blank Chassis and Controls Page 6 18 Line Painter 1200 Chapter 7 TORO Traction Drive System Table of Contents SERVICE AND REPAIRS sss 2 Traction Drive Belt 0 0 a 2 Shift Lever and Linkage 000005 4 Transaxle i ees awk ieee Sa REG EE RE Se 6 Transaxle Service 0 ccc eee 8 DANA MODEL 4360 TEARDOWN AND ASSEMBLY INSTRUCTIONS o 2 LJ a c e S pe Line Painter 1200 Page 7 1 Traction Drive System Service and Repairs Traction Drive Belt Figure 1 Shoulder bolt Idler bracket AANI Removal Fig 1 1 Park machine on a level surface stop engine and re move key from the ignition switch Remove high tension lead from the spark plug and position the lead away from
57. perating the machine Also tighten any loose nuts bolts or screws to ensure machine is in safe operating condition While Operating 1 Operator should be in the operator s position when operating the Line Painter 1200 2 Do not run engine in a confined area without ade quate ventilation Exhaust fumes are hazardous and could possibly be deadly 3 Do not touch engine muffler or exhaust pipe while engine is running or soon after it is stopped These areas could be hot enough to cause burns 4 f abnormal vibration is detected stop machine im mediately and determine source of vibration Correct problems before resuming the use of the machine 5 Use extreme caution when operating the machine in reverse or when pulling the machine rearward 6 Always wear safety goggles or safety glasses with side shields when operating the machine Safety Page 1 2 death To reduce the potential for injury or death comply with the following safety instructions To reduce the potential for injury or death comply with the following safety instructions 3 Since gasoline is highly flammable handle it careful ly A Store fuel in containers specifically designed for this purpose B Do not remove machine fuel tank cap while en gine is hot or running C Do not smoke while handling fuel D Fill fuel tank outdoors and only to within an inch of the top of the tank not the filler neck Do not overfill the fuel tank
58. pray pump 2 To pressure regulator 45 to 55 in Ib 5 1 to 6 2 N m Figure 27 1 Nut 6 Valve ball 2 Cover 7 Spindle 3 O ring 8 Housing 4 O ring 9 O ring 2 used 5 Seat 0 000 to 030 0 0 to 8 mm Figure 28 2 Outlet port 1 Recirculation port Paint System Spray Pump Drive Belt Figure 29 1 Engine pulley 7 Pivot washer 2 Lock nut 8 Cap screw 3 Idler pulley 9 Lock nut 4 Shoulder screw 10 Spray pump 5 Extension spring 11 Pump drive belt 6 Idler bracket 12 Pump pulley Removal Fig 29 1 Drain paint tank see Operator s Manual 2 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug 3 Under chassis rotate idler bracket and pulley to re lease tension on pump drive belt While holding idler pulley away from pump drive belt remove belt from pump pulley Carefully release idler bracket and pulley 4 Remove pump drive belt from engine pulley and ma chine Paint System Page 5 26 13 Set screw 14 Square key 15 Flat washer 16 Lock washer 17 Cap screw Installation Fig 29 1 Position pump drive belt to engine pulley 2 Rotate idler bracket and pulley to allow belt to be installed on pump pulley Carefully release idler bracket and pulley to tension belt 3 Secure high te
59. r 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Class 8 8 Class 10 9 Metric Bolts and Screws Figure 2 Product Records and Maintenance Product Records 5 c o c 7 S o ge ed o Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Grade 1 54 8 with Thin Height Nuts SAE Grade 1 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE Grade 5 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 5 or Stronger Nuts MT MT SAE Grade 8 Bolts Screws Studs amp Thread Size Sems with Regular Height Nuts 6 32 UNC 147 23 6 40 UNF 8 32 UNC 282 56 8 36 UNF 10 24 UNC 339 56 10 32 UNF 1 4 20 UNC 48 7 599 79 1 4 28 UNF 65 10 734 113 5 16 18 UNC 115 4 15 105 15 1186 169 5 16 24 UNF 138 17 128 17 1446 192 3 8 16 UNC 1642 3 8 24 UNF 17 2 7 16 14 UNC 27 3 7 16 20 UNF 29 3 77 8 104 11 115412 120412 163 16 1 2 13 UNC 30 3 1 2 20 UNF 3244 5 8 11 UNC 65 10 88 12 5 8 18 UNF 75 10 95415 129 20 3 4 10 UNC 93 12 140 20 190 27 265 27 359 37 375 38 508 52 300 30 407 41 420 43 569 58 430 45 583 61 600 60 813 81 475 48 644 65 667 66 904 89 NO
60. rankcase The engine drives the spray pump indirectly through pul leys and a V belt The spray pump belt is always ten sioned by a backside idler pulley so the pump is being rotated whenever the engine is running When the pump is rotated the downward stroke of the pump s diaphragm creates suction to allow fluid paint to be drawn from the paint tank to the pump via hoses a ball valve in the paint position and a 40 mesh screen filter Pump design prevents fluid from being pumped back into the suction line Line Painter 1200 Page 5 5 Once to the pump the fluid paint is pushed by the up ward stroke of the pump s diaphragm to the pressure side of the spray system through hoses control valves and the spray nozzle Pump design prevents fluid from being drawn back into the pump Maximum pressure in the system is limited by an adjustable relief valve located in the pump An adjustable pressure regulator is used by the operator to set paint circuit pressure on the Line Painter 1200 Flow in excess of the regulator setting is directed back to the paint tank via a ball valve in the paint position This return flow is used for paint tank agitation An op tional pressure gauge if equipped indicates system pressure A mechanically actuated spool valve is used to turn the spray nozzle on off Spool valve shift occurs when the operator depresses or releases the paint control lever Paint System PAINT WATER ka
61. ront of machine Figs 9 and 10 A Loosen jam nuts that secure cable to chassis bracket Chassis and Controls 6 Flange bushing Page 6 10 7 Flange nut 8 Castor release cable 9 Hair pin B Remove hair pin and clevis pin that secure cable clevis to castor release lever C Slide cable clevis from release lever 4 Note routing of castor release cable Remove cable from machine Installation Fig 8 1 Position castor release cable to machine 2 Connect castor release cable to castor release lever on machine handle A Slide cable end onto castor release lever and se cure with hair pin B Secure cable to handle assembly with jam nut C Make sure that cable boot is positioned over end of cable Line Painter 1200 3 Connect castor release cable to castor release det ent under front of machine Figs 9 and 10 A Secure cable clevis to castor release detent with clevis pin and hair pin B Position cable to chassis bracket C Tighten cable jam nuts to allow castor detent to completely disengage from front castor when castor release lever on handle is pulled against handle D Make sure that cable boot is positioned over end of cable 4 Secure high tension lead to spark plug Figure 9 1 Castor release cable 3 Cable clevis 2 Castor release lever 4 Jam nut o So 1 Cap screw 6 Detent pa 2 Flange nut 7 Flange bushing Ge 3 Flat washer 8 Hair pin o 5 4 Torsion spring 9
62. s Check fuel lines and connections periodically as recom mended in the Operator s Manual Check lines for dete rioration damage leaking or loose connections Replace hoses clamps and connections as necessary Drain and Clean Fuel Tank IMPORTANT If fuel tank is to be drained drain fuel outdoors Drain and clean the fuel tank periodically as recom mended in the Operator s Manual Also drain and clean the fuel tank if the fuel system becomes contaminated or if the machine is to be stored for an extended period NOTE The fuel tank is equipped with an integral filter screen at the tank outlet To clean fuel tank flush tank and fuel hoses out with clean solvent Make sure tank is free of contaminates and debris Fuel Tank Removal Fig 4 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug 2 Allow engine to cool before removing fuel tank Line Painter 1200 Page 3 7 3 Remove high tension lead from the spark plug and position the lead away from the spark plug 4 Close fuel shut off valve Disconnect fuel hose from carburetor inlet 5 Place disconnected hose in appropriate container and open fuel shut off valve to allow fuel tank to drain completely 6 Remove fuel tank using Figure 4 as a guide If fuel tank bracket item 14 removal is necessary remove
63. s item 4 and cap screws item 12 2 Connect suction and pressure hoses to spray pump fittings 3 Return tank support to upright position and secure with flange head screws see Tank Support in this sec tion 4 Apply antiseize lubricant to drive shaft Place square key item 10 in pump shaft Slide pulley onto pump shaft with the pulley hub away from pump Secure pulley to pump with cap screw item 7 lock washer item 8 and flat washer item 6 Tighten pulley set screws 5 Install spray pump drive belt see Spray Pump Drive Belt Installation in this section 6 Secure high tension lead to spark plug 1 Spray pump 2 Suction line in Line Painter 1200 Page 5 29 Figure 31 3 Filter 4 Pressure line out Paint System Spray Pump Service 25 to 30 in Ib 2 8to 3 4 N m 314 15 25 to 30 in Ib mS 2 8 to 3 4 N m Figure 32 1 Pump head 7 Straight fitting 13 Lock washer 5 used 2 Check valve kit 8 O ring 14 Screw 2 long 5 used 3 Wobbler plate diaphragm assembly 9 Filter cover 15 Screw 1 5 long 5 used 4 Gasket 10 O ring 16 Elbow fitting 5 Pump endbell 11 Filter 40 mesh 17 Socket head screw relief valve 6 Bearing 12 Flat washer 10 used Disassembly Fig 32 1 Remove two 2 socket head screws and lock wash ers that secure spray pump to pump drive housing Fig 34 Separate spray pump from drive housing 2 If necessary disassemble pump drive h
64. t 19 Threaded rod 6 Nozzle bracket 13 Adapter cap 20 Wing nut 7 Knob 14 Cap screw 3 used 21 Supply hose Paint System Page 5 32 Rev A Line Painter 1200 Disassembly Fig 36 1 Operate line painter in the flush mode to clean paint tubes 2 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Remove high tension lead from the spark plug and position the lead away from the spark plug 3 Remove spray head components as needed using Figures 36 and 37 as guides Assembly Fig 36 1 Assemble spray head using Figures 36 and 37 as Figure 37 guides If barb fitting item 3 or diaphragm nozzle item 1 Body 4 Adapter cap 10 were removed from nozzle tube apply Saf T Lok 2 Seat gasket 5 Check valve end cap PTFE Pipe Sealant or equivalent to threads of compo 3 Spray nozzle 6 Check valve diaphragm nents before assembly see Thread Sealant for Paint System Fittings in the General Information section 2 Adjust spray head components see Operator s Manual Line Painter 1200 Page 5 33 Rev A Paint System This page is intentionally blank Paint System Page 5 34 Line Painter 1200 Chapter 6 TORO Chassis and Controls Table of Contents SPECIFICATIONS cece ene ee n 2 ADJUSTMENTS 00 cece eee eee 3 Traction Drive Cable 000 cee eee 3 Front Castor Fork 00 00 cece eee ees 4 SERVICE AND REPA
65. t to upright position and secure with flange head screws see Tank Support in this sec tion 5 Secure high tension lead to spark plug Line Painter 1200 1 Ball valve 1 Flush tank 2 Outlet tube FLOW DIRECTI BG 1 Outlet tube from tan Page 5 17 Figure 13 2 Outlet tube location Figure 14 3 Check valve sgp Figure 15 k 2 Tube to ball valve Paint System Check Valve Service The one way check valve that is positioned between the flush water tank and the ball valve see schematic prevents paint from entering the flush water tank when the paint flush lever is moved from the paint position to the flush position and while the machine is operated in the flush mode NOTE If the flush system is not cleaned after use di luted paint may cause check valve and associated hoses to become blocked If the check valve is stuck open paint may enter the flush water tank when the paint flush lever is moved from the paint position to the flush position If the check valve is stuck closed the flush system may not operate 1 Remove flush tank see Flush Tank Removal in this section 2 Remove check valve from tubes see Quick Discon nect Fitting in the General Information section Fig 16 3 Inspect check valve A The spring loaded plunger in the check valve should unseat with very light pressure when pressed on with a suitable probe Take care when pressin
66. ter 1200 Page 4 3 Electrical System Troubleshooting For effective troubleshooting and repairs there must be a good understanding of the electrical circuits and com ponents used on this machine see Electrical Schematic in this chapter Remove all jewelry especially rings and watches before doing any electrical NOTE See the Kawasaki FJ180V Service Manual at troubleshooting or testing the end of Chapter 3 Engine for troubleshooting of en gine electrical problems Starting Problems Engine will not start ON OFF switch is in the OFF Turn switch to ON position ON OFF switch is faulty Replace ON OFF switch Ignition spark plug lead is not Connect high tension lead to spark connected to spark plug plug Electrical wires are loose or Check electrical connections damaged Repair wiring Engine is malfunctioning See Kawasaki FJ180V Service Manual at the end of Chapter 3 Engine Engine will start but will not Electrical wires are loose or Check electrical connections continue to run damaged Repair wiring ON OFF switch is faulty Replace ON OFF switch Engine is malfunctioning See Kawasaki FJ180V Service Manual at the end of Chapter 3 Engine Electrical System Page 4 4 Line Painter 1200 Component Testing For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit e g unplug the ignition switch connector before doing a cont
67. ter gives information about specifications Service and repair parts for the Kawasaki engine used maintenance troubleshooting testing and repair of the to power the Line Painter 1200 are supplied through Kawasaki FJ180V gasoline engine used in the Line your local Toro distributor Be prepared to provide your Painter 1200 distributor with the Toro model and serial number Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the Kawasaki FJ180V Service Manual that is included at the end of this Chapter The use of some specialized test equipment is explained However the cost of the test equipment and the special ized nature of some repairs may dictate that the work be done at an engine repair facility Gasoline Engine Page 3 2 Line Painter 1200 Specifications Item Description Make Designation Kawasaki FJ180V 4 stroke air cooled OHV single cylinder Bore x Stroke 2 6 x 2 1 65 mm x 54 mm Total Displacement 10 9 cu in 179 cc Compression Ratio 8 5 1 Carburetor Float Feed Fixed Main Jet Governor Mechanical High Idle No Load 2800 100 RPM Direction of Rotation Counter Clockwise Facing PTO Shaft Fuel Unleaded Automotive Grade Gasoline Fuel Tank Capacity 4 Quart 3 8 Liter Engine Oil See Operator s Manual Lubrication System Pressure Lubrication
68. the spark plug 2 Remove pump drive belt from machine see Spray Pump Drive Belt Removal in the Service and Repairs section of Chapter 5 Paint System 3 Loosen flange nuts item 9 that secure belt guides to machine Rotate belt guides away from traction drive belt Traction Drive System Traction drive belt 6 Extension spring Idler pulley 7 Pivot washer Lock nut 8 Engine pulley 9 Flange nut 4 used Page 7 2 10 Belt guide 4 used 11 Lock nut 12 Cap screw 13 Transaxle pulley 4 To allow removal of traction drive belt from idler pulley Fig 2 loosen cap screw item 12 and lock nut item 3 that secure idler pulley to idler bracket Remove belt from idler pulley 5 Carefully remove traction belt from engine and trans axle pulleys Remove traction belt from machine Installation Fig 1 1 Position traction drive belt to engine and transaxle pulleys Line Painter 1200 2 Position traction drive belt to idler pulley and bracket making sure that belt is placed between pulley and guide on bracket Fig 2 Tighten cap screw item 12 and lock nut item 3 to secure idler pulley to idler bracket 3 Tension the traction drive belt by depressing the trac tion drive lever operator control Rotate belt guides to al low from 060 to 130 1 5 to 3 3 mm clearance between guide and tensioned traction drive belt Tighten lock nuts to secure guides in place 4 Install pump drive belt to mach
69. ve ports to paint tank Paint System Page 5 24 5 Label hoses connected to ball valves to assist in as sembly Remove hoses from fittings on ball valves Fig 26 see Quick Disconnect Fitting in the General Infor mation section 6 Remove knob item 20 from lever item 19 7 Remove two 2 flange screws item 16 that secure ball valve assembly to tank support 8 Remove ball valve assembly from machine Locate and retrieve rubber washers item 6 that seal ports on ball valves to paint tank Discard rubber washers 9 As necessary remove fittings and lever from ball valves to allow removal of ball valve s from ball valve bracket Line Painter 1200 NOTE Individual components for the ball valves are not available NOTE Ball valve nut threads have thread sealant ap plied during initial assembly Nut removal may be diffi cult 10 If needed disassemble ball valve using Fig 27 as a guide Installation Fig 25 1 If ball valves were disassembled assemble ball valves using Fig 27 as a guide Torque nut 45 to 55 in Ib 5 1 to 6 2 N m NOTE When assembling ball valves and lever to ball valve bracket make sure that valve ball is orientated to upper fitting opening of ball valve assembly and lever is in the paint lowered position 2 Position ball valves and lever to ball valve bracket IMPORTANT Install fittings into ball valves by hand to prevent cross threading the ball valve threads 3

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