Toro 1200 User Manual
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 OPERATING, 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 Manuals 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.
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Part No. 05144SL Rev. A
Service Manual
Line Painter 1200
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUCTION. 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 important instructions which must be followed to prevent damage to systems or components on the
machine.
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E The Toro Company – 2005, 2007
This page is intentionally blank.
Line Painter 1200
Table Of Contents
Chapter 1 – Safety
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 2
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 4
Chapter 2 – Product Records and Maintenance
Product Records
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1
Equivalents and Conversions . . . . . . . . . . . . . . . . 2 – 2
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 – 3
Chapter 3 – Gasoline Engine
Introduction
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 – 4
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 – 5
KAWASAKI FJ180V SERVICE MANUAL
Chapter 4 – Electrical System
Electrical Schematic
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 4
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 2
. . . . . . . . . . . . . . . . . . . . . . . . 4 – 2
Chapter 5 – Paint System
Specifications
Paint Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 3
Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 8
General Information . . . . . . . . . . . . . . . . . . . . . . . . 5 – 9
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 10
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 – 12
Chapter 6 – Chassis and Controls
Specifications
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 – 6
Chapter 7 – Traction Drive System
Service and Repairs
DANA MODEL 4360 TEARDOWN AND ASSEMBLY
INSTRUCTIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2
. . . . . . . . . . . . . . . . . . . . . . . . 7 – 2
SafetyProduct Records
and Maintenance
Engine
Gasoline
SystemSystem
Electrical
Paint
SystemControls
Chassis and
Traction Drive
Line Painter 1200
This page is intentionally blank.
Line Painter 1200
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 4
Chapter 1
Safety
Safety
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, maintenance and storage of the machine. Improper use or
maintenance of the machine can result in injury or
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Before Operating
1. Read and understand the contents of the Operator’s
Manual before starting and operating the machine. Become 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 operating the
machine. Also tighten any loose nuts, bolts or screws to
ensure machine is in safe operating condition.
death. To reduce the potential for injury or death, comply
with the following safety instructions.
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
3. Since gasoline is highly flammable, handle it carefully:
A. Store fuel in containers specifically designed for
this purpose.
B. Do not remove machine fuel tank cap while engine 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.
E. If fuel is spilled, do not start engine. Move the machine away from the area of spillage and allow the
gasoline vapors to dissipate. Properly dispose of any
spilled fuel.
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 adequate 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. If abnormal vibration is detected, stop machine immediately 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
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 operation.
B. Ensure that vehicle traction lever is in neutral, apply 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.
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.
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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. If major repairs are ever needed or assistance is desired, 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
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Line Painter 1200 Page 1 – 3 Safety
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 replacement decals from your Authorized Toro Distributor.
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Safety
Page 1 – 4
Line Painter 1200
Product Records and Maintenance
Table of Contents
Chapter 2
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2
Decimal and Millimeter Equivalents . . . . . . . . . . . . 2
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 3
Fastener Identification . . . . . . . . . . . . . . . . . . . . . . . 3
Product Records
Insert a copy of the Operator’s Manual and Parts Catalog 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 Catalogs for those options at the end of this chapter.
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Maintenance
Maintenance procedures and recommended service intervals for the Line Painter 1200 are covered in the Operator’s Manual. Refer to that publication when
performing regular equipment maintenance.
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Inch Series) . . . . . . . . . . . . . . . 4
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Metric Fasteners) . . . . . . . . . . 5
Other Torque Specifications
Conversion Factors
. . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . 6
Product Records
and Maintenance
Line Painter 1200 Page 2 – 1 Product Records and Maintenance
Equivalents and Conversions
Product Records and Maintenance
Page 2 – 2
Line Painter 1200
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 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.
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Fastener Identification
As noted in the following tables, torque values should be
reduced by 25% 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 performed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
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Product Records
and Maintenance
Grade 1 Grade 5 Grade 8
Inch Series Bolts and Screws
Figure 1 Figure 2
Class 8.8 Class 10.9
Metric Bolts and Screws
Line Painter 1200 Page 2 – 3 Product Records and Maintenance
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs &
Thread Size
8 with Thin Sems** with Regular Height Nuts Sems** with Regular Height Nuts Sems** with Regular Height Nuts
Height Nuts (SAE J995 Grade 2 or Stronger Nuts) (SAE J995 Grade 2 or Stronger Nuts) (SAE J995 Grade 5 or Stronger Nuts)
in–lb in–lb N–cm in–lb N–cm in–lb N–cm
# 6 – 32 UNC 15 + 2 169 + 23 23 + 3 262 + 34
# 6 – 40 UNF
# 8 – 32 UNC 29 + 3 328 + 34 41 + 5 463 + 56
# 8 – 36 UNF
# 10 – 24 UNC 42 + 5 475 + 56 60 + 6 678 + 68
# 10 – 32 UNF
1/4 – 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1130 + 113 140 + 15 1582 + 169
1/4 – 28 UNF 53 + 7 65 + 10 734 + 113 115 + 12 1299 + 136 160 + 17 1808 + 192
5/16 – 18 UNC 115 + 15 105 + 15 1186 + 169 200 + 25 2260 + 282 300 + 30 3390 + 339
5/16 – 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2542 + 282 325 + 33 3672 + 373
3/8 – 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 5 58 + 7
3/8 – 24 UNF 17 + 2 18 + 2 24 + 3 35 + 4 47 + 5 50 + 6 68 + 8
7/16 – 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9
7/16 – 20 UNF 29 + 3 29 + 3 39 + 4 55 + 6 75 + 8 77 + 8 104 + 11
10 + 2
13 + 2
18 + 2
ft–lb ft–lb N–m ft–lb N–m ft–lb N–m
13 + 2
25 + 5
30 + 5
147 + 23
17 + 2 192 + 23 25 + 3 282 + 34
282 + 56
31 + 4 350 + 45 43 + 5 486 + 56
339 + 56
48 + 5 542 + 56 68 + 7 768 + 79
1/2 – 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 11 142 + 15
1/2 – 20 UNF 32 + 4 53 + 7 72 + 9 85 + 9 115 + 12 120 + 12 163 + 16
5/8 – 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 21 285 + 28
5/8 – 18 UNF 75 + 10 95 + 15 129 + 20 170 + 18 230 + 24 240 + 24 325 + 33
3/4 – 10 UNC 93 + 12 140 + 20 190 + 27 265 + 27 359 + 37 375 + 38 508 + 52
3/4 – 16 UNF 115 + 15 165 + 25 224 + 34 300 + 30 407 + 41 420 + 43 569 + 58
7/8 – 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81
7/8 – 14 UNF 155 + 25 260 + 30 353 + 41 475 + 48 644 + 65 667 + 66 904 + 89
** A Sems screw is a self–tapping screw equipped with
a captive washer.
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
NOTE: Torque values may have to be reduced when
engine oil or thread sealant such as Loctite.
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.
NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the mini
mum proof load specified in SAE J429. The tolerance is
approximately +
10% of the nominal torque value. Thin
height nuts include jam nuts.
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Product Records and Maintenance
Page 2 – 4
Line Painter 1200
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws and Studs with
Thread Size
M5 X 0.8 57 + 6 in–lb 644 + 68 N–cm 78 + 8 in–lb 881 + 90 N–cm
M6 X 1.0 96 + 10 in–lb 1085 + 113 N–cm 133 + 14 in–lb 1503 + 158 N–cm
M8 X 1.25 19 + 2 ft–lb 26 + 3 N–m 28 + 3 ft–lb 38 + 4 N–m
M10 X 1.5 38 + 4 ft–lb 52 + 5 N–m 54 + 6 ft–lb 73 + 8 N–m
M12 X 1.75 66 + 7 ft–lb 90 + 10 N–m 93 + 10 ft–lb 126 + 14 N–m
M16 X 2.0 166 + 17 ft–lb 225 + 23 N–m 229 + 23 ft–lb 310 + 31 N–m
M20 X 2.5 325 + 33 ft–lb 440 + 45 N–m 450 + 46 ft–lb 610 + 62 N–m
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.
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.
Regular Height Nuts
(Class 8 or Stronger Nuts)
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately +
nominal torque value.
Class 10.9 Bolts, Screws and Studs with
Regular Height Nuts
(Class 10 or Stronger Nuts)
10% of the
Product Records
and Maintenance
Line Painter 1200 Page 2 – 5 Product Records and Maintenance
Other Torque Specifications
SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts
Recommended Torque
Thread Size
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 50 + 10 ft–lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Size Baseline Torque*
No. 6 – 32 UNC 20 + 5 in–lb
No. 8 – 32 UNC 30 + 5 in–lb
Thread Size
7/16 – 20 UNF
Grade 5
1/2 – 20 UNF
Grade 5
M12 X 1.25
Class 8.8
M12 X 1.5
Class 8.8
** For steel wheels and non–lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
No. 6 18 20 20 + 5 in–lb
No. 8 15 18 30 + 5 in–lb
Threads per Inch
Type A Type B
Recommended Torque**
65 + 10 ft–lb 88 + 14 N–m
80 + 10 ft–lb 108 + 14 N–m
80 + 10 ft–lb 108 + 14 N–m
80 + 10 ft–lb 108 + 14 N–m
orque* Baseline Torque*
No. 10 – 24 UNC 38 + 7 in–lb
1/4 – 20 UNC 85 + 15 in–lb
5/16 – 18 UNC 110 + 20 in–lb
3/8 – 16 UNC 200 + 100 in–lb
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–lb
No. 10 12 16 38 + 7 in–lb
No. 12 11 14 85 + 15 in–lb
* Hole size, material strength, material thickness & finish
must be considered when determining specific torque
values. All torque values are based on non–lubricated
fasteners.
Product Records and Maintenance
Page 2 – 6
Line Painter 1200
Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4
Fuel Shut–off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 5
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
KAWASAKI FJ180V SERVICE MANUAL
Chapter 3
Gasoline Engine
Engine
Gasoline
Line Painter 1200 Page 3 – 1 Gasoline Engine
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 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.
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Service and repair parts for the Kawasaki engine used
to power the Line Painter 1200 are supplied through
your local Toro distributor. Be prepared to provide your
distributor with the Toro model and serial number.
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
Oil Capacity (Including Oil Filter) 0.9 Quart (0.85 Liter)
Engine
Gasoline
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
General Information
Fuel Shut–off Valve
The fuel shut off valve is positioned in the fuel hose between 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 engine.
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1
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, engage 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.
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1
2
IMPORTANT: Never clean engine with pressurized
water. Water could enter and contaminate the fuel
system.
2. Remove rewind starter and clean rotating screen
(Fig.2).
3. If necessary, remove engine cover, rotating screen
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 engine cover are reinstalled to the engine if removed.
5. Attach high tension lead to the spark plug.
3
3
Figure 2
1. Rotating screen 3. Cooling fins
2. Blower housing
1
2
Engine
Gasoline
3
4
Figure 3
1. Rewind starter 3. Rotating screen
2. Engine cover 4. Blower housing
Line Painter 1200 Page 3 – 5 Gasoline Engine
Fuel Tank
10
11
12
13
2
3
1
4
3
5
3
6
14
3
7
1. Fuel tank
2. Fuel tank cap
3. Hose clamp (4 used)
4. Fuel hose
5. Fuel shut off valve
9
RIGHT
FRONT
8
Figure 4
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. Fuel tank bracket
Line Painter 1200Gasoline Engine Page 3 – 6
DANGER
Because gasoline is highly flammable, use caution 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 Connections
Check fuel lines and connections periodically as recommended in the Operator’s Manual. Check lines for deterioration, damage, leaking or loose connections.
Replace hoses, clamps and connections as necessary.
Drain and Clean Fuel Tank
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
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).
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Engine
Gasoline
IMPORTANT: If fuel tank is to be drained, drain fuel
outdoors.
Drain and clean the fuel tank periodically as recommended 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, engage 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.
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).
Line Painter 1200 Page 3 – 7 Gasoline Engine
Engine
11
15
14
12
16
14
14
17
13
2
10
9
8
1
14
3
4
3
7
20 to 30 ft–lb
(27 to 41 N–m)
RIGHT
FRONT
6
250 to 450 in–lb
(28 to 51 N–m)
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
Removal (Fig. 5)
1. Park machine on a level surface, stop engine, engage 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. If engine is to be disassembled, it may be easier to
drain oil from engine before removing engine from machine (see Operator’s Manual).
18
50 to 60 ft–lb
(68 to 81 N–m)
Loctite #242
19
5
Figure 5
14. Hose clamp (4 used)
15. Fuel hose
16. Fuel shut off valve
17. Fuel hose
18. Engine pulley
19. Cap screw
4. Remove fuel tank from machine (see Fuel Tank Removal 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).
3. Close fuel shut off valve. Disconnect fuel hose from
carburetor inlet.
Line Painter 1200Gasoline Engine Page 3 – 8
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.
8. Install fuel tank to machine (see Fuel Tank Installation in this section).
9. If machine is equipped with a hour meter, install hour
meter pickup wire to spark plug lead on engine.
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 crankshaft
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).
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 inlet. Open fuel shut–off valve.
1
-
2
Figure 6
1. Fuel shut off valve 2. Stop switch wire
Engine
Gasoline
5. Position engine on the frame.
6. Align holes in frame with engine mounting holes. Secure engine to frame with four (4) screws. Torque
screws from 250 to 450 in–lb (28 to 51 N–m).
7. On the 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.
4
2
1
1
2
3
Figure 7
1. Flange nut 3. Pump drive belt
2. Belt guide 4. Engine pulley
Line Painter 1200 Page 3 – 9 Gasoline Engine
This page is intentionally blank.
Gasoline Engine Page 3 – 10 Line Painter 1200
Table of Contents
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . 5
On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hourmeter (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 4
Electrical System
System
Electrical
Line Painter 1200 Page 4 – 1 Electrical System
Electrical Schematic
HIGH TENSION LEAD
BLACK
BLACK
IGNITION COIL
ENGINE
MAGNETO
(FLYWHEEL)
HOUR METER
(OPTIONAL)
BROWN
ON\OFF SWITCH
is open in the ON
position.
ON/OFF SWITCH
BLACK
Electrical System
Page 4 – 2
Line Painter 1200
Special Tools
Multimeter
The multimeter can test electrical components and circuits 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 current is not allowed through the meter. This excess
current can cause damage to circuits not designed to
carry it.
Spark Tester – TOR4036
The spark tester can test magneto ignitions. The spark
tester determines if ignition is present.
-
Figure 1
Figure 2
System
Electrical
Line Painter 1200 Page 4 – 3 Electrical System
Troubleshooting
For effective troubleshooting and repairs, there must be
CAUTION
Remove all jewelry, especially rings and
watches, before doing any electrical
troubleshooting or testing.
Starting Problems
Problem Possible Causes Correction
a good understanding of the electrical circuits and com
ponents used on this machine (see Electrical Schematic
in this chapter).
NOTE: See the Kawasaki FJ180V Service Manual at
the end of Chapter 3 – Engine for troubleshooting of en
gine electrical problems.
-
-
Engine will not start. ON/OFF switch is in the OFF
position.
ON/OFF switch is faulty. Replace ON/OFF switch.
Ignition spark plug lead is not
connected to spark plug.
Electrical wires are loose or Check electrical connections.
damaged. Repair wiring.
Engine is malfunctioning. See Kawasaki FJ180V Service
Engine will start, but will not
continue to run.
Electrical wires are loose or
damaged.
ON/OFF switch is faulty. Replace ON/OFF switch.
Engine is malfunctioning. See Kawasaki FJ180V Service
Turn switch to ON.
Connect high tension lead to spark
plug.
Manual at the end of Chapter 3 –
Engine.
Check electrical connections.
Repair wiring.
Manual at the end of Chapter 3 –
Engine.
Electrical System
Page 4 – 4
Line Painter 1200
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