Page 2 - This page is intentionally blank.
This page is intentionally blank. Line Painter 1200
Page 3 - Table Of Contents
Table Of Contents Chapter 1 – Safety Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 2 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 4 Chapter 2 – Product Records and Maintenance Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 –...
Page 5 - Chapter 1; Table of Contents
Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Service . . . . . . . . . . . . ...
Page 6 - Before Operating
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 awarenes...
Page 7 - Maintenance and Service
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...
Page 8 - Safety and Instruction Decals
Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Line Painter 1200. If any decal becomes illegible or 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 Dist...
Page 9 - Chapter 2
Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2 Decimal and Millimeter Equivalents . . . . . ....
Page 10 - Equivalents and Conversions
Equivalents and Conversions Product Records and Maintenance Page 2 – 2 Line Painter 1200
Page 11 - Torque Specifications; Fastener Identification
Torque 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 Specif...
Page 14 - Other Torque Specifications; Conversion Factors
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Thread Size Recommended Torque Square Head Hex Socket 1/4 – 20 UNC 140 + 20 in–lb 73 + 12 in–lb 5/16 – 18 UNC 215 + 35 in–lb 145 + 20 in–lb 3/8 – 16 UNC 35 + 10 ft–lb 18 + 3 ft–lb 1/2 – 13 UNC 75 + 15 ft–lb...
Page 15 - Chapter 3
Chapter 3 Gasoline Engine Table of Contents INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Fuel Shut–off Valve . . . . . . . . . . . . ...
Page 16 - Introduction
Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing and repair of the Kawasaki FJ180V gasoline engine used in the Line Painter 1200. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are de...
Page 17 - Specifications
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) 280...
Page 18 - General Information; Fuel Shut–off Valve
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 befo...
Page 19 - Service and Repairs; Cooling System
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- ...
Page 20 - Fuel Tank
Line Painter 1200 Gasoline Engine Page 3 – 6 Fuel Tank 1. Fuel tank 2. Fuel tank cap 3. Hose clamp (4 used) 4. Fuel hose 5. Fuel shut off valve 6. Fuel hose 7. Engine 8. Screw (2 used) 9. Washer head screw (2 used) 10. Nut (2 used) 11. Frame 12. Fuel tank support 13. Washer head screw (2 used) 14. F...
Page 21 - DANGER
DANGER 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...
Page 22 - Engine
Line Painter 1200 Gasoline Engine Page 3 – 8 Engine Figure 5 1. Engine 2. Oil drain valve 3. O–ring 4. Drain extension 5. Screw (6 used) 6. Washer head screw (2 used) 7. Nut (2 used) 8. Frame 9. Fuel tank support 10. Washer head screw (2 used) 11. Fuel tank cap 12. Fuel tank 13. Fuel tank bracket 14...
Page 25 - Chapter 4
Chapter 4 Electrical System Table of Contents ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4 COMPONENT TESTING . . . . . . . . . . . . . . . ....
Page 26 - Electrical Schematic
Electrical Schematic ENGINE ON/OFF SWITCH IGNITION COIL BLACK BLACK BLACK HOUR METER (OPTIONAL) BROWN ON\OFF SWITCH is open in the ON position. MAGNETO HIGH TENSION LEAD (FLYWHEEL) Electrical System Page 4 – 2 Line Painter 1200
Page 27 - Special Tools; Multimeter
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 ...
Page 28 - Starting Problems
Troubleshooting CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Starting Problems For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and com- ponents used on this machine (see Elec...
Page 29 - Component Testing
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 continuity check). On/Off Switch The on/off switch is used to shut the engine off. When the on/off switc...
Page 31 - Chapter 5
Chapter 5 Paint System Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 12 PAINT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Paint Tank . . . . . . . . . . . . . . . . . . . ...
Page 33 - Paint Schematic
Paint Schematic Line Painter 1200 (OFF) (OFF) (OFF POSITION) Hydraulic Schematic Paint System Line Painter 1200 Page 5 – 3 Paint System
Page 34 - Circuit Operation; Paint Circuit
Circuit Operation Return (Agitation) Suction Flow Paint Circuit Line Painter 1200 (OFF) (OFF) Working Pressure Paint System Page 5 – 4 Line Painter 1200
Page 36 - Flush Circuit
Return Suction Flow Flush Circuit Line Painter 1200 (OPEN) Working Pressure Paint System Page 5 – 6 Line Painter 1200
Page 38 - Troubleshooting
ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Troubleshooting Problem ÁÁÁ...
Page 39 - Quick Disconnect Fittings; Thread Sealant for Paint System Fittings
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 ...
Page 40 - Adjustments; Spray Pump Relief Valve Adjustment
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...
Page 42 - Paint Tank
Line Painter 1200 Page 5 – 12 Paint System Service and Repairs Paint Tank 1. Paint tank 2. Nut 3. Tank support 4. Flat washer 5. Jam nut 6. Elbow fitting 7. Tank clamp (2 used) 8. Rubber washer 9. Outlet port 10. Ball valve 11. Recirculation port 12. O–ring 13. Drain valve 14. Elbow fitting 15. Valv...
Page 44 - Tank Support
Line Painter 1200 Page 5 – 14 Paint System Tank Support 1. Handle assembly 2. Flange head screw (4 used) 3. Chassis 4. Flush tank 5. Tank support 6. Paint tank Figure 7 2 3 4 1 5 6 FRONT RIGHT
Page 48 - Check Valve Service
Line Painter 1200 Page 5 – 18 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 pos...
Page 50 - Paint Shutoff Valve
Line Painter 1200 Page 5 – 20 Paint System Paint Shutoff Valve 1. Paint tank 2. Tank support 3. Elbow fitting 4. Paint shutoff valve 5. Flange nut 6. Straight fitting 7. Tee fitting 8. Plug 9. Extension spring 10. Lever 11. Hair pin 12. Pin 13. Cotterless pin 14. Cap screw 15. Flat washer 16. Manifo...
Page 52 - Pressure Regulator
Line Painter 1200 Page 5 – 22 Paint System Pressure Regulator 1. Pressure regulator 2. Flange head screw (2 used) 3. Straight fitting 4. Tee fitting 5. Tank support 6. Elbow fitting 7. Bracket 8. Cap screw Figure 22 FRONT RIGHT 2 3 4 1 5 6 7 8 144 to 156 in–lb (16.3 to 17.6 N–m) 120 to 132 in–lb(13....
Page 54 - Ball Valve
Line Painter 1200 Page 5 – 24 Paint System Ball Valve 1. Paint tank 2. Jam nut 3. Elbow fitting 4. Flat washer 5. Slotted washer 6. Rubber washer 7. Outlet port 8. Ball valve bracket 9. Straight fitting 10. Hose clamp 11. Tee fitting 12. O–ring 13. Ball valve 14. Elbow fitting 15. Drain valve bracke...
Page 56 - Spray Pump Drive Belt
Line Painter 1200 Page 5 – 26 Paint System Spray Pump Drive Belt 1. Engine pulley 2. Lock nut 3. Idler pulley 4. Shoulder screw 5. Extension spring 6. Idler bracket 7. Pivot washer 8. Cap screw 9. Lock nut 10. Spray pump 11. Pump drive belt 12. Pump pulley 13. Set screw 14. Square key 15. Flat washe...
Page 58 - Spray Pump
Line Painter 1200 Page 5 – 28 Paint System Spray Pump 1. Tank support 2. Flange head screw (4 used) 3. Spray pump assembly 4. Flange nut (3 used) 5. Pulley 6. Flat washer 7. Cap screw 8. Lock washer 9. Set screw 10. Square key 11. Chassis 12. Cap screw (3 used) 13. Flush tank 14. Paint tank Figure 3...
Page 60 - Spray Pump Service
Line Painter 1200 Page 5 – 30 Paint System Spray Pump Service 1. Pump head 2. Check valve kit 3. Wobbler plate/diaphragm assembly 4. Gasket 5. Pump endbell 6. Bearing 7. Straight fitting 8. O–ring 9. Filter cover 10. O–ring 11. Filter (40 mesh) 12. Flat washer (10 used) 13. Lock washer (5 used) 14. ...
Page 62 - Spray Head
Line Painter 1200 Page 5 – 3 2 (Rev. A) Paint System Spray Head 1. Hose 2. Hose clamp 3. Barb fitting 4. Nozzle tube 5. Wing nut 6. Nozzle bracket 7. Knob 8. Shield 9. Nozzle bracket 10. Diaphragm nozzle 11. Spray nozzle 12. Seat gasket 13. Adapter cap 14. Cap screw (3 used) 15. Clamp bracket 16. Sp...
Page 65 - Chapter 6
Chapter 6 Chassis and Controls Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Traction Drive Cable . . . . . . . . . . . . . . . . . . . . . . . . . 3 Front Castor Fork . . . . . . ....
Page 67 - Traction Drive Cable
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. Ad...
Page 68 - Front Castor Fork
Line Painter 1200 Chassis and Controls Page 6 – 4 Front Castor Fork 1. Front castor wheel 2. Socket head screw (2 used) 3. Lock washer (2 used) 4. Castor plate 5. Castor fork Figure 2 FRONT RIGHT 2 3 4 1 5 If the Line Painter 1200 does not follow a straight line when the castor detent is engaged, fr...
Page 70 - Wheels
Line Painter 1200 Chassis and Controls Page 6 – 6 Service and Repairs Wheels 1. Front castor wheel 2. Bushing 3. Cap screw 4. Castor fork 5. Lock nut 6. E–ring 7. Washer 8. Rear wheel 9. Square key 10. Thrust washer 11. Spacer Figure 4 FRONT RIGHT 2 3 4 1 5 6 7 8 10 11 9 ANTISEIZE LUBRICANT
Page 72 - Brake Cable
Line Painter 1200 Chassis and Controls Page 6 – 8 Brake Cable 1. Brake lever 2. Knob 3. Compression spring 4. Shoulder screw 5. Handle assembly 6. Brake cable 7. Hairpin 8. Flange nut Figure 6 FRONT RIGHT 2 3 4 1 5 6 7 8 Brake Cable Attachment Point Note: Console shownremoved from handle for clarity...
Page 74 - Castor Release Cable
Line Painter 1200 Chassis and Controls Page 6 – 10 Castor Release Cable 1. Castor release lever 2. Rubber bumper 3. Traction lever 4. Cap screw 5. Flat washer 6. Flange bushing 7. Flange nut 8. Castor release cable 9. Hair pin Figure 8 2 3 4 1 5 6 7 8 9 6 Removal (Fig. 8) 1. Park machine on a level ...
Page 78 - Paint Control Cable
Line Painter 1200 Chassis and Controls Page 6 – 14 Paint Control Cable 1. Paint control lever 2. Bushing 3. Bushing 4. Flange nut 5. Hair pin 6. Paint control cable 7. Rubber bumper 8. Cap screw 9. Flat washer Figure 13 2 3 4 1 5 6 7 8 9 3 Removal (Fig. 13) 1. Park machine on a level surface, stop e...
Page 83 - Chapter 7
Chapter 7 Traction Drive System Table of Contents SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 2 Traction Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Shift Lever and Linkage . . . . . . . . . . . . . . . . . . . . . . 4 Transaxle . . . . . . . . . . . . . . . ...
Page 84 - Traction Drive Belt
Line Painter 1200 Traction Drive System Page 7 – 2 Service and Repairs Traction Drive Belt 1. Traction drive belt 2. Idler pulley 3. Lock nut 4. Shoulder bolt 5. Idler bracket 6. Extension spring 7. Pivot washer 8. Engine pulley 9. Flange nut (4 used) 10. Belt guide (4 used) 11. Lock nut 12. Cap scr...
Page 86 - Shift Lever and Linkage
Line Painter 1200 Traction Drive System Page 7 – 4 Shift Lever and Linkage 1. Handle 2. Console 3. Knob 4. Nylon washer 5. Console shift lever 6. Bushing 7. Hair pin 8. Clevis pin 9. Shift lever (on transaxle) 10. Shift link 11. Control rod 12. Bell crank 13. Pivot shaft 14. Washer head screw 15. Ro...
Page 88 - Transaxle
Line Painter 1200 Traction Drive System Page 7 – 6 Transaxle 1. Transaxle assembly 2. Flange nut (4 used) 3. Thrust washer 4. Wheel and tire 5. Square key 6. Spacer 7. Brake return spring 8. Carriage screw (4 used) 9. Cap screw 10. Lock washer 11. Spacer 12. Shift lever 13. Drive pulley 14. External...
Page 90 - Transaxle Service
Line Painter 1200 Traction Drive System Page 7 – 8 Transaxle Service Figure 5 FRONT RIGHT 2 3 4 1 5 6 7 8 10 11 12 9 13 15 14 16 17 18 19 20 21 22 25 26 23 24 27 28 29 30 31 34 35 32 33 36 37 38 39 19 19 21 26 40 41 42 43 44 45 46 47 48 49 11 12 50 51 52 53 53 54 56 57 50 54 55 56 59 58 60 60 62 63 ...
