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

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

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

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

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

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

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

Component Testing

For accurate resistance and/or continuity checks, electrically 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 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.

-

1

Figure 3

1. On/Off switch

System

Electrical

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 operation. 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 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 Operator’s Manual.

-

Figure 5

Electrical System

Page 4 – 6

Line Painter 1200

Table of Contents

Chapter 5

Paint System

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

PAINT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 4

Paint Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Flush Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 8

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 9

Paint/Flush Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Quick Disconnect Fittings . . . . . . . . . . . . . . . . . . . . 9

Thread Sealant for Paint System Fittings . . . . . . . 9

ADJUSTMENTS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spray Pump Relief Valve Adjustment 10. . . . . . . . .

SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 12

Paint Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Tank Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Flush (Water) Tank . . . . . . . . . . . . . . . . . . . . . . . . . 16

Check Valve Service . . . . . . . . . . . . . . . . . . . . . . . . 18

Paint Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . 20

Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 22

Ball Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Spray Pump Drive Belt . . . . . . . . . . . . . . . . . . . . . . 26

Spray Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Spray Pump Service . . . . . . . . . . . . . . . . . . . . . . . . 30

Spray Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Paint

System

Line Painter 1200 Page 5 – 1 Paint System

Specifications

Item Description

Pump Diaphragm Pump with 5 Chambers

Pump Capacity 4 GPM (15.1 LPM) Relief Pressure 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

(OFF)

(OFF POSITION)

Line Painter 1200

Hydraulic Schematic

Paint

System

Line Painter 1200 Page 5 – 3 Paint System

Circuit Operation

(OFF)

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 displacement 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 crankcase.

The engine drives the spray pump indirectly through pulleys and a V–belt. The spray pump belt is always tensioned 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.

Once to the pump, the fluid (paint) is pushed by the upward 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

Line Painter 1200 Page 5 – 5 Paint System

(OPEN)

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 displacement 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 upward 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 the system is limited by an adjustable relief valve located in the dia phragm pump.

Flow in excess of the adjustable pressure regulator setting is directed back to the flush (water) suction line via a ball valve (in the flush position).

Flow through the flush circuit is used to dilute and remove 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, diluted 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

Line Painter 1200 Page 5 – 7 Paint System

Troubleshooting

Á

Problem

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Spray system leaks fluid.

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Á

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Spray pressure is low.

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No spray output from nozzle.

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No spray output from nozzle in the flush mode.

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Nozzle leaks when paint valve is

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closed.

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Paint is being pumped into the flush

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tank.

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Paint System Page 5 – 8 Line Painter 1200

Possible Cause

Fitting(s) or hose(s) are loose or damaged.

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Á

O–ring(s) or seal(s) are missing or damaged.

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Á

Suction line is restricted.

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Á

Filter screen is plugged.

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Á

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Á

Pressure regulator is damaged or incorrectly adjusted.

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Á

Spray nozzle is worn or damaged.

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Á

Check valve in diaphragm nozzle is stuck or plugged.

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Á

Engine speed is low.

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Á

Pressure relief valve in spray pump is stuck.

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Á

Pump drive belt is slipping.

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Spray pump is faulty.

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Á

Paint tank is empty.

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Á

Paint/Flush lever is in the off position.

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Á

Hose(s) are pinched or kinked.

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Á

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Á

Dried paint in system.

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Á

Filter screen is plugged.

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Á

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Á

Spray nozzle is clogged or damaged.

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Á

Check valve in diaphragm nozzle is stuck or plugged.

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Á

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Á

Paint shutoff valve is faulty.

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Á

Pump drive belt is slipping, damaged or broken.

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Spray pump is faulty.

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Flush tank is empty.

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Á

Check valve in flush tank outlet tube is stuck closed.

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Á

Check valve diaphragm in diaphragm nozzle body is leaking or damaged.

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Á

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Paint shutoff valve is not seating.

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Á

Paint control cable is not adjusted correctly (see Paint Control

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Cable in the Service and Repairs section of Chapter 6 – Chassis

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and Controls).

Check valve in flush tank outlet tube is stuck open.

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Á

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.

2

If the paint filter is to be cleaned and paint is in the paint tank, turn the paint/flush lever to OFF (engine not run ning) to prevent paint leakage.

Quick Disconnect Fittings

The Line Painter 1200 uses several quick disconnect fittings that provide excellent sealing and allow easy disassembly. 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.

-

3

Figure 1

1. Paint lever (in OFF) 3. Paint mode

2. Flush mode

2

1

-

3

1

Paint

System

Figure 2

1. Fitting 3. Hose

2. Release collar

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. If a 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) Paint System

TPS (PTFE Sealant) to the fitting threads before

installation. If an alternate sealant is used, make sure that it is compatible with nylon and polypropylene materials.

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.

-

2

1

Figure 3

1. Spray pump 2. Socket head screw

Paint System Page 5 – 10 Line Painter 1200

This page is intentionally blank.

Paint

System

Line Painter 1200 Page 5 – 11 Paint System

Service and Repairs

Paint Tank

144 to 156 in–lb

(16.3 to 17.6 N–m)

192 to 216 in–lb

(21.7 to 24.4 N–m)

6

5

4

2

1

10

8

11

3

19

5

20

7

8

9

10

192 to 216 in–lb (21.7 to 24.4 N–m)

14

13

12

15

16

17

18

RIGHT

FRONT

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

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. Drain paint tank (see Operator’s Manual). Remove tank lid and strainer.

Figure 4

15. Valve bracket

16. Flange head screw

17. Flange head screw (4 used)

18. Pump assembly

19. Flush tank

20. Slotted washer

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 section). Loosen and remove elbow fitting.

Line Painter 1200Page 5 – 12Paint System

6. Remove two (2) jam nuts that secure tank to ball valve ports (Fig. 5). Locate and retrieve washers (items 4 and 20).

2

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. Discard 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 in–lb (21.7 to 24.4 N–m).

1. Drain valve

2. Elbow fitting

5

4

3

2

1

3

4

Figure 5

3. Jam nut

4. Agitation tube

6

10 to 12 in–lb

(1.1 to 1.4 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 tighten the four screws (item 17) to secure tank to machine.

6. Install elbow fitting (item 6) and torque from 144 to 156 in–lb (16.3 to 17.6 N–m). Install agitation tube to elbow 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 in–lb (1.1 to 1.4 N–m).

8. Install high tension lead to spark plug when service is complete.

1. Paint tank

2. O–ring

3. Lid flange

Figure 6

4. Strainer

5. Lid

6. Screw (8 used)

Paint

System

Line Painter 1200 Page 5 – 13 Paint System

Tank Support

6

1

5

2

3

RIGHT

FRONT

1. Handle assembly

2. Flange head screw (4 used)

4

Figure 7

3. Chassis

4. Flush tank

5. Tank support

6. Paint tank

Line Painter 1200Page 5 – 14Paint System

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, 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.

4. Remove the hairpin and flat washer that secure the shift rod to the shift bellcrank at the rear of the machine (Fig. 8).

2

1

5

3

4

Figure 8

1. Shift rod 4. Flat washer

2. Shift bellcrank 5. Fitting

3. Hairpin

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 upright 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

2

3

Figure 9

1. Tank support 3. Front flange screw

2. Rear flange screw

Paint

System

Figure 10

Line Painter 1200 Page 5 – 15 Paint System

Flush (Water) Tank

RIGHT

1

2

14

3

4

5

6

7

8

9

10

13

12

11

FRONT

1. Paint tank

2. Tank support

3. Cap

4. Cap insert

5. Gasket

6. Stud

7. Flush tank

8. Extension spring

9. Tank support rod

10. Spray pump assembly

Removal (Fig. 11)

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. Operate line painter in the flush mode until the flush tank is empty.

3. 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.

4. Tip tank support to gain access to flush tank (see Tank Support in this section).

Figure 11

1. Flush tank

2. Extension spring

11. Elbow fitting

12. Clamp

13. Bushing

14. Flange head screw (4 used)

2

3

1

Figure 12

3. Tank support rod

Line Painter 1200Page 5 – 16Paint System

5. Unhook extension spring from hole in tank support (Fig. 12). Remove spring and tank support rod from machine.

6. Remove flush tank outlet tube from elbow fitting on bottom of ball valve (Fig. 13 and 14) (see Quick Disconnect Fitting in the General Information section).

7. Remove flush tank with outlet tube attached from machine.

1

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 support to upright position and secure with flange head screws (see Tank Support in this section).

5. Secure high tension lead to spark plug.

2

Figure 13

1. Ball valve 2. Outlet tube location

1

2

3

Figure 14

1. Flush tank

2. Outlet tube

3. Check valve

Paint

System

2

1

Figure 15

1. Outlet tube from tank 2. Tube to ball valve

Line Painter 1200 Page 5 – 17 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, diluted 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 Disconnect 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 pressing on the plunger not to damage the check valve or to allow contaminates into the valve.

4

Figure 16

1. Flush tank

2. Outlet tube (from tank)

2

1

2

3

3. Check valve

4. Outlet tube (to valve)

1

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 necessary.

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 17

1. Outlet tube from tank 2. Tube to ball valve

Line Painter 1200Page 5 – 18Paint System

This page is intentionally blank.

Paint

System

Line Painter 1200 Page 5 – 19 Paint System

Paint Shutoff Valve

PAINT SHUTOFF VALVE

18

20

1

16

192 to 216 in–lb

(21.7 to 24.4 N–m)

17

19

13

RIGHT

11

FRONT

Figure 18

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

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. Drain paint tank (see Operator’s Manual). Operate line painter in the flush mode to clean paint tubes.

12

10

14

15

3

4

5

2

9

8

6

7

15. Flat washer

16. Manifold block

17. O–ring

18. O–ring

19. O–ring

20. Spool

144 to 156 in–lb (16.3 to 17.6 N–m)

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 manifold block.

2. 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.

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 1200Page 5 – 20Paint System

Paint Shutoff Valve Removal (Fig. 18)

7. Connect extension spring (item 9) to lever.

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, 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.

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 extension spring (item 9) from lever (item

10).

6. Remove hair pin (item 11) and pin (item 12) that secure 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)

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.

-

4

3

Figure 19

1. Cable 3. Inlet hose

2. Outlet hose 4. Paint shutoff valve

-

1

2

-

1

Paint

System

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

2. If 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.

-

1. Pivot cotterless pin 2. Spool cotterless pin

Figure 20

18.

3. Position valve to tank support and install cap screw (item 14), flat washer (item 15) and flange nut (item 5).

5

34

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.

1. Manifold block 4. O–ring

2. Spool 5. O–ring

3. O–ring

1

2

Figure 21

Line Painter 1200 Page 5 – 21 (Rev. A) Paint System

Pressure Regulator

144 to 156 in–lb

(16.3 to 17.6 N–m)

7

6

5

8

RIGHT

FRONT

Figure 22

1. Pressure regulator

2. Flange head screw (2 used)

3. Straight fitting

4. Tee fitting

5. Tank support

6. Elbow 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, 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.

1

2

3

4

7. Bracket

8. Cap screw

120 to 132 in–lb (13.6 to 14.9 N–m)

5. Label hoses connected to pressure regulator to assist in assembly. Remove hoses from fittings on pressure regulator (Fig. 23) (see Quick Disconnect Fitting in the General Information section).

6. Remove pressure regulator from machine using Figure 22 as a guide.

7. If necessary, remove fittings from pressure regulator.

3. Remove flush tank (see Flush Tank Removal in this section).

4. If equipped, remove pressure gauge from machine.

Line Painter 1200Page 5 – 22Paint System

Disassembly (Fig. 24)

NOTE: Individual components for the pressure regula-

tor are not available. If pressure regulator is disassembled for cleaning, take care not to damage regulator components.

1

3

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 disassembly. 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 spark plug.

2

4

Figure 23

1. Pressure regulator 3. To paint shutoff valve

2. To RH ball valve 4. To spray pump

7

4

6

5

3

2

1

Figure 24

1. Knob 5. Spring pin

2. Collar 6. Jam nut

3. Spring 7. Housing

4. Poppet

Paint

System

Line Painter 1200 Page 5 – 23 (Rev. A) Paint System

Ball Valve

144 to 156 in–lb

(16.3 to 17.6 N–m)

192 to 216 in–lb

(21.7 to 24.4 N–m)

84 to 108 in–lb

(9.5 to 12.2 N–m)

RIGHT

1

20

3

2

4

192 to 216 in–lb

2

(21.7 to 24.4 N–m)

5

144 to 156 in–lb

(16.3 to 17.6 N–m)

84 to 108 in–lb (9.5 to 12.2 N–m)

14

19

18

21

24

22

23

6

7

8

9

10

13

11

12

15

16

FRONT

Figure 25

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 bracket

16. Flange screw (5 used)

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, 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.

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 valve ports to paint tank.

17

17. Tank support

18. Elbow fitting

19. Lever

20. Knob

21. Screw

22. Flat washer

23. Spacer

24. Recirculation port

5. Label hoses connected to ball valves to assist in assembly. Remove hoses from fittings on ball valves (Fig.

26) (see Quick Disconnect Fitting in the General Information 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 1200Page 5 – 24Paint System

NOTE: Individual components for the ball valves are not available.

10.Install flush tank (see Flush (Water) Tank Installation in this section).

NOTE: Ball valve nut threads have thread sealant applied during initial assembly. Nut removal may be difficult.

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–lb (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. 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 clearance 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 between 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).

11. Secure high tension lead to spark plug.

3

Figure 26

1. To spray pump 3. Lever (paint position)

2. To pressure regulator

9

4

7

6

45 to 55 in–lb

(5.1 to 6.2 N–m)

4

2

8

5

3

Figure 27

1. Nut

2. Cover

3. O–ring

4. O–ring

5. Seat

0.000” to .030” (0.0 to .8 mm)

6. Valve ball

7. Spindle

8. Housing

9. O–ring (2 used)

2

1

2

Paint

System

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.

1. Recirculation port 2. Outlet port

Figure 28

Line Painter 1200 Page 5 – 25 (Rev. A) Paint System

Spray Pump Drive Belt

13

14

12

15

16

11

17

1

2

3

4

5

8

6

7

9

10

Figure 29

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

Removal (Fig. 29)

1. Drain paint tank (see Operator’s Manual).

2. 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.

3. Under chassis, rotate idler bracket and pulley to release 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.

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 tension lead to spark plug.

4. Remove pump drive belt from engine pulley and machine.

Line Painter 1200Page 5 – 26Paint System

This page is intentionally blank.

Paint

System

Line Painter 1200 Page 5 – 27 Paint System

Spray Pump

14

1

11

RIGHT

FRONT

1. Tank support

2. Flange head screw (4 used)

3. Spray pump assembly

4. Flange nut (3 used)

5. Pulley

13

12

6. Flat washer

7. Cap screw

8. Lock washer

9. Set screw

10. Square key

9

10

8

2

3

4

5

6

7

Figure 30

11. Chassis

12. Cap screw (3 used)

13. Flush tank

14. Paint tank

Removal (Fig. 30)

1. Drain paint tank (see Operator’s Manual).

2. 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.

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 1200Page 5 – 28Paint System

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.

3

4

Installation (Fig. 30)

1. Position spray pump to machine chassis. Secure pump to chassis with three (3) flange nuts (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

2

Figure 31

1. Spray pump 3. Filter

2. Suction line (in) 4. Pressure line (out)

Paint

System

Line Painter 1200 Page 5 – 29 Paint System

Spray Pump Service

25 to 30 in–lb

(2.8 to 3.4 N–m)

11

10

9

1. Pump head

2. Check valve kit

3. Wobbler plate/diaphragm assembly

4. Gasket

5. Pump endbell

6. Bearing

14

13

12

8

7

6

Figure 32

7. Straight fitting

8. O–ring

9. Filter cover

10. O–ring

11. Filter (40 mesh)

12. Flat washer (10 used)

15

8

25 to 30 in–lb

(2.8 to 3.4 N–m)

16

17

1

2

3

4

5

13. Lock washer (5 used)

14. Screw (2” long) (5 used)

15. Screw (1.5” long) (5 used)

16. Elbow fitting

17. Socket head screw (relief valve)

Disassembly (Fig. 32)

1. Remove two (2) socket head screws and lock washers that secure spray pump to pump drive housing (Fig.

34). Separate spray pump from drive housing.

2. If necessary, disassemble pump drive housing assembly (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.

5. Carefully separate pump head from pump endbell. Remove and discard gasket. Separate wobbler plate/diaphragm 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. Remove and discard o–ring (item 8).

DIAGONAL LINE

Figure 33

Line Painter 1200Page 5 – 30Paint System

8. If necessary, remove fittings in filter (item 7) and/or pump head (item 16) by sliding retainer and pulling fitting from housing. Remove and discard o–rings (item 8).

Inspection

1. If paint has dried on internal pump parts, components or complete pump replacement will most likely be required.

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.

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 individual valves are damaged, replace check valve 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 outlet 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.

9. Secure spray pump to pump drive housing with two (2) socket head screws and lock washers. Torque socket 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 assembly, install new o–ring, slide fitting or filter into housing and secure with retainer.

1

2

4

5

6

22 to 28 in–lb

(2.5 to 3.2 N–m)

7

6

3

4

5

22 to 28 in–lb

8

(2.5 to 3.2 N–m)

Paint

System

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–lb (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. Make sure bearings contact drive shaft shoulder.

1. Spray pump

2. Pump gasket

3. Pump drive housing

4. Lock washer

3

2

1. Wobbler plate/diaphragm assembly

2. Check valve kit

3. Outlet check valve (5 used)

4. O–ring

Figure 34

5. Socket head screw

6. Retaining ring

7. Drive shaft

8. Ball bearing

4

1

Figure 35

Line Painter 1200 Page 5 – 31 Paint System

Spray Head

17

18

17

18

19

20

21

1

2

168 to 216 in–lb (19 to 24.4 N–m)

3

Saf–T–Lok PTFE

Pipe Sealant

16

5

4

5

6

7

8

9

8

15

1. Hose

2. Hose clamp

3. Barb fitting

4. Nozzle tube

5. Wing nut

6. Nozzle bracket

7. Knob

14

Figure 36

8. Shield

9. Nozzle bracket

10. Diaphragm nozzle

11. Spray nozzle

12. Seat gasket

13. Adapter cap

14. Cap screw (3 used)

13

12

10

11

Saf–T–Lok PTFE

Pipe Sealant

144 to 156 in–lb

(16.3 to 17.6 N–m)

15. Clamp bracket

16. Spray arm

17. Stop

18. Jam nut

19. Threaded rod

20. Wing nut

21. Supply hose

Line Painter 1200Page 5 – 32 (Rev. A)Paint System

Disassembly (Fig. 36)

1. Operate line painter in the flush mode to clean paint tubes.

2. 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.

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 guides. If barb fitting (item 3) or diaphragm nozzle (item

10) were removed from nozzle tube, apply Saf–T–Lok

PTFE Pipe Sealant (or equivalent) to threads of compo-

nents before assembly (see Thread Sealant for Paint System Fittings in the General Information section).

2. Adjust spray head components (see Operator’s Manual).

1

2

6

5

3

4

Figure 37

1. Body 4. Adapter cap

2. Seat gasket 5. Check valve end cap

3. Spray nozzle 6. Check valve diaphragm

Paint

System

Line Painter 1200 Page 5 – 33 (Rev. A) Paint System

This page is intentionally blank.

Paint System Page 5 – 34 Line Painter 1200

Table of Contents

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Traction Drive Cable . . . . . . . . . . . . . . . . . . . . . . . . . 3

Front Castor Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 6

Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Castor Release Cable . . . . . . . . . . . . . . . . . . . . . . 10

Traction Drive Cable Paint Control Cable Front Castor Fork

. . . . . . . . . . . . . . . . . . . . . . . . 12

. . . . . . . . . . . . . . . . . . . . . . . . 14

. . . . . . . . . . . . . . . . . . . . . . . . . . 16

Chapter 6

Chassis and Controls

Line Painter 1200 Page 6 – 1 Chassis and Controls

Controls

Chassis and

Specifications

Item Description

Tire Pressure

Front Castor Tire Rear Tire

18 to 20 PSI (1.2 to 1.4 Bar) 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, 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. Make sure that traction lever on handle is released.

3. Adjust location of traction cable jam nuts so that traction 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.

4

5

1. Traction drive cable 4. Cable spring

2. Idler bracket 5. Cable boot

3. Jam nut

3

1

Figure 1

2

Line Painter 1200 Page 6 – 3 Chassis and Controls

Controls

Chassis and

Front Castor Fork

RIGHT

4

5

3

2

FRONT

1. Front castor wheel

2. Socket head screw (2 used)

3. Lock washer (2 used)

4. Castor plate

If the Line Painter 1200 does not follow a straight line when the castor detent is engaged, front castor fork adjustment is necessary.

Adjustment

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. 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 access 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.

1

Figure 2

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

.750”

(19 mm)

3. Loosen two (2) socket head screws (item 2) that secure castor plate to castor fork.

Figure 3

Line Painter 1200Chassis and Controls Page 6 – 4

This page is intentionally blank.

Controls

Chassis and

Line Painter 1200 Page 6 – 5 Chassis and Controls

Service and Repairs

Wheels

RIGHT

FRONT

ANTISEIZE

LUBRICANT

3

2

1. Front castor wheel

2. Bushing

3. Cap screw

4. Castor fork

4

5

1

5. Lock nut

6. E–ring

7. Washer

8. Rear wheel

Figure 4

11

10

9. Square key

10. Thrust washer

11. Spacer

9

8

6

7

Line Painter 1200Chassis and Controls Page 6 – 6

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. 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.

1

2

4

5

-

3

6

1

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 removed, install bushing and bearings to wheel assembly (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.

1. Outside bearing

2. Bushing

3. Rim and tire assembly

Figure 5

4. Grease fitting

5. Bearing

6. Valve stem

D. Lubricate grease fitting on front wheel (see Operator’s Manual).

2. To install rear wheel:

A. Apply antiseize lubricant to transaxle shaft. Position square key (item 9) in transaxle slot.

B. Slide wheel onto transaxle shaft.

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 Chassis and Controls

Controls

Chassis and

Brake Cable

2

RIGHT

1

7

6

5

Brake Cable

Attachment

8

3

4

Point

Note: Console shown removed from handle

for clarity

FRONT

1. Brake lever

2. Knob

3. Compression spring

4. Shoulder screw

5. Handle assembly

6. Brake cable

Removal (Fig. 6)

1. Park machine on a level surface, stop engine and remove 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 assembly.

B. Remove hair pin that retains cable end to brake lever.

C. Slide cable end from brake lever.

Figure 6

7. Hairpin

8. Flange nut

3. Disconnect brake cable from brake lever on transaxle (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 machine.

Installation (Fig. 6)

1. Position brake cable to machine.

Line Painter 1200Chassis and Controls Page 6 – 8

2. Connect brake cable to brake lever on handle (Fig.

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):

4. Secure high tension lead to spark plug.

1

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.

D. Make sure that cable boot is positioned over end of cable.

2

3

Figure 7

1. Brake cable spring 3. Cable jam nut

2. Brake lever

Line Painter 1200 Page 6 – 9 Chassis and Controls

Controls

Chassis and

Castor Release Cable

1

2

3

4

9

8

1. Castor release lever

2. Rubber bumper

3. Traction lever

5

6

7

6

Figure 8

4. Cap screw

5. Flat washer

6. Flange bushing

7. Flange nut

8. Castor release cable

9. Hair pin

Removal (Fig. 8)

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. Disconnect castor release cable from castor release lever on machine handle:

A. Loosen jam nut that secures cable to handle assembly.

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 front of machine (Figs. 9 and 10):

A. Loosen jam nuts that secure cable to chassis bracket.

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 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.

Line Painter 1200Chassis and Controls Page 6 – 10

3. Connect castor release cable to castor release detent 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.

3

1. Castor release cable

2. Castor release lever

2

4

1

4

Figure 9

3. Cable clevis

4. Jam nut

1

10

1. Cap screw

2. Flange nut

3. Flat washer

4. Torsion spring

5. Spacer

9

8

Figure 10

3

4

5

7

6

6. Detent

7. Flange bushing

8. Hair pin

9. Clevis pin

10. Castor release cable

2

Controls

Chassis and

Line Painter 1200 Chassis and ControlsPage 6 – 11

Traction Drive Cable

1

10

9

8

7

6

4

5

3

2

4

Figure 11

1. Traction lever

2. Flat washer

3. Cap screw

4. Flange bushing

5. Traction drive cable

6. Hair pin

7. Flange nut

Removal (Fig. 11)

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. Disconnect traction drive cable from traction lever on machine handle:

A. Loosen jam nut that secures cable to handle assembly.

B. Remove hair pin that retains cable end to traction lever.

C. Slide cable end from traction lever.

8. Bushing (2 used)

9. Bushing

10. Castor release lever

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 1200Chassis and Controls Page 6 – 12

2. Connect traction drive cable to traction lever on machine 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.

3. Connect traction drive cable to traction idler bracket under machine (Fig. 12):

A. Connect cable spring to idler bracket.

2

3

1

B. Position cable to chassis bracket.

C. Adjust traction drive cable (see Traction Drive 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.

1. Traction drive cable

2. Cable spring

Figure 12

3. Idler bracket

Line Painter 1200 Page 6 – 13 Chassis and Controls

Controls

Chassis and

Paint Control Cable

8

9

1

2

3

4

Figure 13

1. Paint control lever

2. Bushing

3. Bushing

4. Flange nut

5. Hair pin

6. Paint control cable

Removal (Fig. 13)

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. Disconnect paint control cable from paint control lever on machine handle:

7

6

7. Rubber bumper

8. Cap screw

9. Flat washer

5

3. Disconnect paint control cable from paint shutoff valve (Fig. 14):

A. Loosen jam nuts that secure cable to chassis bracket.

B. Remove two (2) pins that secure paint shutoff valve lever to shutoff valve. Shift position of lever to allow cable clevis removal.

A. Loosen jam nut that secures cable to handle assembly.

B. Remove hair pin that retains cable end to paint control lever.

C. Slide cable end from paint control lever.

C. Remove hair pin and clevis pin that secure cable clevis to paint shutoff valve lever.

4. Note routing of paint control cable. Remove cable from machine.

Line Painter 1200Chassis and Controls Page 6 – 14

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 secure with hair pin.

2

4

1

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 clevis 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 control lever has from .050” to .100” (1.3 to 2.5 mm) freeplay. Readjust cable if necessary.

3

Figure 14

1. Paint control cable 3. Paint shutoff valve

2. Paint shutoff valve lever 4. Cable boot

1

2

5. Secure high tension lead to spark plug.

Figure 15

1. Pivot cotterless pin 2. Spool cotterless pin

Controls

Chassis and

Line Painter 1200 Page 6 – 15 Chassis and Controls

Front Castor Fork

14

13

12

9

11

10

9

8

7

4

3

RIGHT

FRONT

2

Figure 16

1. Castor wheel

2. Bushing

3. Socket head screw (2 used)

4. Lock washer (2 used)

5. Lock nut

6. Castor fork

7. Cap screw

8. Castor plate

9. Bushing

10. Grease fitting

Removal (Fig. 16)

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. Raise front of machine to allow front castor fork removal. Support machine to prevent it from shifting during repair.

3. Depress castor release lever to disengage caster detent from castor fork.

6

5

1

11. Chassis

12. Wave washer

13. Rebound washer

14. Flange head screw

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 chassis.

4. Remove castor wheel from castor fork (see Wheel Removal in this section).

Line Painter 1200Chassis and Controls Page 6 – 16

Installation (Fig. 16)

6. Carefully lower machine to ground.

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 top of castor fork. Secure castor fork to ma chine with flange head screw (item 13).

5. Install castor wheel to castor fork (see Wheel Installation in this section).

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 section).

-

Line Painter 1200 Page 6 – 17 Chassis and Controls

Controls

Chassis and

This page is intentionally blank.

Chassis and Controls Page 6 – 18 Line Painter 1200

Table of Contents

SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 2

Traction Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Shift Lever and Linkage . . . . . . . . . . . . . . . . . . . . . . 4

Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Transaxle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DANA MODEL 4360 TEARDOWN AND ASSEMBLY

INSTRUCTIONS

Chapter 7

Traction Drive System

Line Painter 1200 Page 7 – 1 Traction Drive System

System

Traction Drive

Service and Repairs

Traction Drive Belt

1

13

12

3

2

4

5

6

7

8

9

10

11

10

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)

Removal (Fig. 1)

1. Park machine on a level surface, stop engine 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. 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.

10

FRONT

RIGHT

Figure 1

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 transaxle pulleys. Remove traction belt from machine.

Installation (Fig. 1)

1. Position traction drive belt to engine and transaxle pulleys.

Line Painter 1200Traction Drive System Page 7 – 2

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 traction drive lever operator control. Rotate belt guides to allow 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 machine (see Spray Pump Drive Belt Installation in the Service and Repairs section of Chapter 5 – Paint System).

2

3

1

4

5. Check traction drive belt cable adjustment (see Traction Drive Cable in the Adjustments section of Chapter 6 – Chassis).

6. Secure high tension lead to spark plug.

Figure 2

1. Traction drive belt 3. Idler pulley

2. Idler bracket 4. Bracket belt guide

Line Painter 1200 Page 7 – 3 Traction Drive System

System

Traction Drive

Shift Lever and Linkage

1

Note: Console shown removed from handle

for clarity

2

3

RIGHT

FRONT

1. Handle

2. Console

3. Knob

4. Nylon washer

5. Console shift lever

8

7

6

4

5

7

10

11

4

9

12

6

4

7

4

15

6

7

13

14

Figure 3

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. Rod fitting

Line Painter 1200Traction Drive System Page 7 – 4

Disassembly (Fig. 3)

Assembly (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.

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 control rod for proper shifting.

3. Secure high tension lead to spark plug.

Line Painter 1200 Page 7 – 5 Traction Drive System

System

Traction Drive

Transaxle

RIGHT

FRONT

4

15

16

1. Transaxle assembly

2. Flange nut (4 used)

3. Thrust washer

4. Wheel and tire

5. Square key

6. Spacer

4

8

7

6

5

9

10

11

ANTISEIZE

3

LUBRICANT

2

14

12

ANTISEIZE

LUBRICANT

13

3

1

ANTISEIZE

LUBRICANT

5

6

16

15

Figure 4

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 snap ring

15. Washer

16. E–ring

Removal (Fig. 4)

1. Park machine on a level surface, stop engine 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 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).

6. Chock front castor wheel. Raise machine so that rear of machine is off the ground. Support machine to prevent it from shifting during transaxle removal.

7. Remove rear wheels (see Wheel Removal in the Service and Repairs section of Chapter 6 – Chassis).

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. Locate and retrieve woodruff key (not shown).

Line Painter 1200Traction Drive System Page 7 – 6

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).

-

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 – Chassis).

9. Connect shift linkage to shift lever on transaxle (see Shift Lever and Linkage in this section).

10.Lower machine to ground.

-

3. Raise transaxle to machine frame.

4. Secure transaxle to machine frame with four (4) carriage screws and flange nuts.

5. Install rear wheels (see Wheel Installation in the Service 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.

11. Secure high tension lead to spark plug.

12.Verify that machine will track in a straight line. If necessary, adjust front castor fork (see Front Castor Fork Adjustment in Chapter 6 – Chassis and Controls).

Line Painter 1200 Page 7 – 7 Traction Drive System

System

Traction Drive

Transaxle Service

19

37

50

11

38

49

51

36

39

35

48

34

40

11

52

41

47

42

33

43

19

53

44

30

32

45

29

54

30 to 40 in–lb

(3.4 to 4.5 N–m)

46

28

27

26

55

56

54

31

25

53

21

1

3

5

11

13

16

10

24

4

12

14

12

15

17

18

23

22

21

20

240 to 300 in–lb

2

(27.1 to 33.9 N–m)

6

8

19

7

9

FRONT

RIGHT

69

57

67

Figure 5

56

64

68

61

66

65

60

63

58

62

60

26

50

160 to 200 in–lb

(18.1 to 22.6 N–m)

59

Line Painter 1200Traction Drive System Page 7 – 8

1. Screw

2. Detent cover

3. Detent spring (2 used)

4. Detent ball (2 used)

5. Cap plug

6. Shifter boot

7. Screw (16 used)

8. Upper housing

9. 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)

Figure 5 (Continued)

24. Spur gear (15T)

25. Drive shaft

26. Shim washer

27. Bevel gear (36T)

28. Sprocket (9T)

29. Spacer

30. Washer

31. Chain

32. Woodruff key

33. Intermediate shaft

34. Clutch key

35. Clutch collar

36. Spur gear (12T)

37. Retaining ring

38. Sprocket (18T)

39. Spacer

40. Spur gear (35T)

41. Spur gear (27T)

42. Spur gear (19T)

43. Spacer

44. Washer

45. Flange bearing

46. Oil seal

47. Idler shaft

48. Combination gear

49. Washer

50. Neoprene washer

51. Plain washer

52. LH axle

53. Miter gear (12T)

54. Retaining ring

55. Spur gear (32T)

56. Miter gear (12T)

57. Cross shaft

58. RH axle

59. Lock nut

60. Screw

61. Bracket

62. Washer

63. Brake actuating lever

64. Dowel pin (2 used)

65. Brake jaw

66. Brake puck spacer

67. Brake puck

68. Brake disc

69. Lower housing

NOTE: For service of the transaxle, see the Dana Mod-

el 4360 Teardown and Reassembly Instructions at the end of this chapter.

NOTE: After transaxle has been disassembled and cleaned, pack transaxle with 12 to 16 ounces of #4300 Shell Darina “D” grease before assembly.

Line Painter 1200 Page 7 – 9 Traction Drive System

System

Traction Drive

This page is intentionally blank.

Traction Drive System Page 7 – 10 Line Painter 1200

Toro 1200 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Table Of Contents

Safety Instructions

Before Operating

While Operating

Maintenance and Service

Safety and Instruction Decals

Product Records

Maintenance

Equivalents and Conversions

Torque Specifications

Fastener Identification

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)

Other Torque Specifications

Introduction

Specifications

General Information

Service and Repairs

Cooling System

Fuel Tank

Engine

Electrical Schematic

Special Tools

Multimeter

Troubleshooting

Component Testing

On/Off Switch

Hourmeter (Optional)

Specifications

Paint Schematic

Circuit Operation

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

Service and Repairs

Paint Tank

Tank Support

Flush (Water) Tank

Check Valve Service

Paint Shutoff Valve

Pressure Regulator

Ball Valve

Spray Pump Drive Belt

Spray Pump

Spray Pump Service

Spray Head

Specifications

Adjustments

Traction Drive Cable

Front Castor Fork

Service and Repairs

Wheels

Brake Cable

Castor Release Cable

Traction Drive Cable

Paint Control Cable

Front Castor Fork

Service and Repairs

Traction Drive Belt

Shift Lever and Linkage

Transaxle

Transaxle Service