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Pioneer Athletics 3500SP Repair Manual

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Repair, Parts
Airless Line Striper
For the application of line striping materials. For professional use only. For outdoor use
only. Not approved for use in explosive atmospheres or hazardous locations.
Model: 25M230
3300 psi (22.8 MPa, 228 bar) Maximum Operating Pressure
Important Safety Instructions
Read all warnings and instructions in this manual, related manuals, and on the
equipment. Be familiar with the controls and the proper usage of the equipment.
Save these instructions.
Related Manuals:
3A4557
Operation
3A4408
Gun
309250
Pump
ti30376a
3A4558F
EN

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Summary of Contents for Pioneer Athletics 3500SP

  • Page 1 Repair, Parts 3A4558F Airless Line Striper For the application of line striping materials. For professional use only. For outdoor use only. Not approved for use in explosive atmospheres or hazardous locations. Model: 25M230 3300 psi (22.8 MPa, 228 bar) Maximum Operating Pressure Important Safety Instructions Read all warnings and instructions in this manual, related manuals, and on the equipment.

  • Page 2: Table Of Contents

    Contents Contents Warnings ....... . . 3 Drive Wheels ......26 Grounding Procedure (For Flammable Materials Removal .

  • Page 3: Warnings

    Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these sym- bols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard sym- bols and warnings not covered in this section may appear throughout the body of this manual where applicable.
  • Page 4 Warnings EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the influence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated system component.
  • Page 5 Warnings PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to: • Protective eyewear, and hearing protection. •...

  • Page 6: Grounding Procedure

    Grounding Procedure (For Flammable Materials Only) Grounding Procedure 1. Perform Grounding Procedure if using flammable materials. (For Flammable Materials Only) 2. Set pump switch OFF. Turn engine OFF by pressing the engine kill switch at the controls, or by moving the lever on the engine.

  • Page 7: Maintenance

    Maintenance Maintenance DAILY: Check hose for wear and damage. ANNUALLY: • Replace spark plug. DAILY: Check gun safety for proper operation. • Replace air filter. DAILY: Check pressure drain valve for proper • Replace pre-cleaner. operation. • Service fuel system. DAILY: Check and fill the gas tank.

  • Page 8: Troubleshooting

    Troubleshooting Troubleshooting Problem Cause Solution Engine won’t start Engine is out of gas Refill gas tank. Briggs & Stratton Owner’s Manual. Engine oil level is low Check oil level. Replenish oil, if necessary. Briggs & Stratton Owner’s Manual. Spark plug is disconnected or damaged Connect spark plug cable or replace spark plug.
  • Page 9 Troubleshooting Problem Cause Solution Pump output is low Strainer is clogged Clean strainer. See pump manual. Piston ball is not seating Service piston ball. See pump manual. Piston packings are worn or damaged Replace packings. See pump manual. O-ring in pump is worn or damaged Replace o-ring.

  • Page 10: Displacement Pump

    Displacement Pump Displacement Pump Removal 5. Loosen jam nut by hitting firmly with a hammer. Unscrew pump. 1. Stop pump with piston rod (29) in its lowest position. 2. Perform Pressure Relief Procedure, page 6. 3. Loosen two screws (32) and remove pump rod cover (107).

  • Page 11: Installation

    Displacement Pump Installation 3. Screw jam nut down onto pump until nut stops. Screw pump up into drive housing until top threads of pump are flush with drive housing face. Back off pump and jam nut to align pump outlet to side. Tighten jam nut by hand, then tap 1/8 to 1/4 turn with a 20 oz (maximum) hammer to approximately If pin works loose, parts could break off due to force...

  • Page 12: Drive Housing And Connecting Rod

    Drive Housing and Connecting Rod Drive Housing and Connecting Rod Removal NOTICE DO NOT use drive housing screws (34) to align or seat bearing housing with drive housing. Align these parts with locating pins to avoid premature bearing wear. 7. Install screws (34) in drive housing. Torque evenly to 1.

  • Page 13: Pinion Assembly/Clutch Armature/Clamp

    Pinion Assembly/Clutch Armature/Clamp Pinion Assembly/Clutch Armature/Clamp Pinion Assembly/Clutch 5. Remove four screws (42) and lock washers (35). Install two screws in threaded holes (E) in rotor. Armature Removal Alternately tighten screws until rotor comes off. Pinion Assembly If pinion assembly (44) is not removed from clutch housing (45), do 1.

  • Page 14: Installation

    Pinion Assembly/Clutch Armature/Clamp Clutch Armature Pinion Assembly 8. Use an impact wrench or wedge something 1. Check o-ring (44e) and replace if missing or between clutch armature (39) and clutch housing to damaged. hold engine shaft during removal. 2. Tap pinion shaft (44c) in with plastic mallet. 9.

  • Page 15: Clamp Removal

    Pinion Assembly/Clutch Armature/Clamp Clamp Removal 1. Remove engine. See Engine Removal, page 17. 4. Loosen two screws (36) on clamp (38). 2. Drain gasoline from tank according to Briggs & 5. Push screwdriver into slot in clamp (38) and remove Stratton manual.

  • Page 16: Clutch Housing

    Clutch Housing Clutch Housing Removal Installation 1. Remove clamp. Perform Clamp Removal, page 15. 1. Push on clutch housing (45). 2. Remove four screws (51) and lock washers (50) that 2. Install four cap screws (51) and lock washers (50) hold clutch housing (45) to engine.

  • Page 17: Engine

    Engine Engine Removal NOTE: All service to the engine must be performed by a Briggs & Stratton authorized service dealer. 1. Disconnect all necessary wiring. 2. Remove two lock nuts (111) and screws (110) from base engine, and screw (145) from clutch housing (45) 3.

  • Page 18: Pressure Control Transducer

    Pressure Control Transducer Pressure Control Transducer Removal Installation 1. Remove two screws (32) and open cover (62a). 1. Install o-ring (99) and transducer (155) in filter hous- ing (67). Torque to 35 - 45 ft-lb. 2. Disconnect transducer (155) cable from control board (62e).

  • Page 19: Pressure Control (On/Off Switch)

    Pressure Control (On/Off Switch) Pressure Control (On/Off Switch) Removal Installation 1. Remove two screws (32) and open cover (62a). 1. Install new ON/OFF switch (62d) so tabs of switch snap into place on inside of cover. 2. Disconnect ON/OFF switch connector from pres- sure control board (342).

  • Page 20: Pressure Adjust Potentiometer

    Pressure Adjust Potentiometer Pressure Adjust Potentiometer Removal Installation 1. Remove two screws (32) and open cover (62a). 1. Install spacer (62g) on potentiometer (62b). 2. Disconnect potentiometer (62b) cable from control 2. Install potentiometer, shaft nut, lock washer and board (62e). potentiometer knob (62c).

  • Page 21: Battery

    Battery Battery Removal 3. Unscrew M5 terminal screws (358) to disconnect battery from wire harness. 1. Shut off engine, turn off the self-propelled drive system, switch to neutral and engage the parking brake. Neutral ti30424a 4. Remove battery (321) from bracket (320). ti30421a 2.

  • Page 22: Installation

    Drive Motor Drive Motor Installation 1. Place battery (321) into bracket (320) and connect the red wire to the positive terminal and the black wire to the negative terminal. NOTICE Removal DO NOT reverse the positive and negative battery wires. This will damage the motor control board.
  • Page 23 Drive Motor 3. Remove the rear chain guard (318). 5. Loosen the two bolts (314) that secure the motor mount to the frame and slide the motor completely forward to loosen the chain (316). Loosen the two set screws on the motor sprocket (313). ti30428a 4.

  • Page 24: Installation

    Drive Motor Installation 3. Slide the motor bracket (310) back to leave about 1/8” slack in the chain (316), and tighten the motor mount bolts (314). Torque to 30-40 ft-lb (41-54 N·m). 1. Place a drop of blue thread locking liquid on the threads of each of the four M6 motor screws (312).
  • Page 25 Drive Motor 4. Adjust the motor sprocket (313) so that it is in-line with 6. Reconnect the battery (321) or replace the fuse. Turn the axle sprocket, then place a drop of blue thread ON the self-propelled drive. With the brake ON and locking liquid onto the threads of each set screw and the right wheel securely elevated just enough to be off secure the motor sprocket in place.

  • Page 26: Drive Wheels

    Drive Wheels Drive Wheels Removal 3. While holding the wheel (3) to keep the axle from spinning, loosen and remove the axle nut (307). Slide the wheel off the axle (300) making sure to retain the key (306). 1. Shut off engine and turn off the self-propelled drive system and switch to neutral.

  • Page 27: Drive Switch

    Drive Switch Drive Switch Removal 4. Remove the strain relief bushing (333) and disconnect the blue wire from (-A) on the control board and from the black motor wire. Disconnect the 1. Shut off engine, turn off self-propelled drive system, white wire from (HI) on the control board (62e) and switch to neutral and engage the parking brake.

  • Page 28: Installation

    Drive Switch Installation 4. Replace the strain relief bushing (333) and close control box cover (62a). 1. Install the switch into the housing and connect the wire harness to the switch. ti30454a 5. With the self-propelled drive system switch in the OFF position, and the drive switch in “N”, connect the battery or insert the fuse.

  • Page 29: Drive/Axle Bearings

    Drive/Axle Bearings Drive/Axle Bearings Removal 3. While holding the wheel (3) to keep the axle (300) from spinning, loosen and remove the axle nut (307). Slide the wheel off the axle making sure to retain the key (306). 1. Shut off the engine and turn off the self-propelled drive system and switch to neutral.

  • Page 30: Installation

    Drive/Axle Bearings 6. Remove the axle bracket nuts (309) and bolts (308) to 8. If replacing the axle bearings, unbolt each bearing disconnect the axle assembly from the striper frame. (304 and 305) from the axle bracket (302). ti30461a Installation 1.
  • Page 31 Drive/Axle Bearings 3. Bolt the axle assembly to the frame and torque to 6. Wrap the chain (316) around the axle and motor 30-40 ft-lb (40.7-54.2 N·m). sprockets and reconnect using the master link. Slight repositioning of the motor may be required. 4.

  • Page 32: Drive Chain

    Drive Chain Drive Chain Removal Installation 1. Wrap the chain around the axle and motor sprocket and reconnect using the master link. 1. Shut off the engine, turn off the self-propelled drive system, switch to neutral and engage parking brake. Neutral ti30421a ti30509a...

  • Page 33: Motor Control Board

    Motor Control Board Motor Control Board Removal 3. Open the control box cover (62a) and carefully disconnect the seven wires that are connected to the male spade terminals and the one white 1. Shut off engine, turn off self-propelled drive system, potentiometer wire.

  • Page 34: Installation

    Motor Control Board Installation NOTICE DO NOT reverse the positive and negative battery wires. 1. Locate control board (62e) on the four threaded studs in This will damage the motor control board. control box cover (62a) and secure using four mounting nuts (62f) torqued to 16-20 in-lb (1.8-2.3 N·m).

  • Page 35: Speed Control

    Speed Control Speed Control Removal 3. Remove the speed knob (62h) using a 5/64” allen wrench, the friction o-ring (62k), the retaining nut, and the spacer (62g). 1. Shut off engine, turn off self-propelled drive system, switch to neutral and engage parking brake. Neutral ti30421a 2.

  • Page 36: Installation

    Speed Control Installation 3. Reconnect the three speed control wires. White to the other white wire, orange to “LO,” and red to “WP”. 1. Slide the rubber spacer (62g) onto the speed poten- tiometer, insert the potentiometer into the hole in the cover (62a), and secure using the retaining nut torqued to 8-11 in-lb (0.9-1.2 N·m), then slide the friction o-ring (62k) onto the stud.

  • Page 37: Troubleshooting

    Troubleshooting Troubleshooting Drive System 3A4558F Repair, Parts...

  • Page 38: Fluid Pump Runs Constantly

    Troubleshooting Fluid Pump Runs Constantly 1. Perform Pressure Relief Procedure, page 6, turn prime valve forward to SPRAY position, and turn power switch OFF. 2. Remove control box cover. Troubleshooting Procedure: With a pressure gauge plumbed into Pump problem. See the proper fluid the paint hose, start the engine.

  • Page 39: Control Board Malfunction

    Troubleshooting Control Board Malfunction Troubleshooting Procedure (see following page for actual steps): Remove control box cover. Turn sprayer ON. Observe control board Green and Red LED Lights. Go to step 1. Replace the No light Does switch switch. Normal Operation test positive? Once Control board...

  • Page 40: Control Board Malfunction (Steps)

    Troubleshooting Control Board Malfunction (Steps) STEP 3. STEP 2. STEP 1. 10-12 DC Leave engine Turn engine Turn 12 -20 AC BEEP running and ON. Set engine turn switch meter to AC OFF and ON. Turn volts and set meter potentiometer connect wires to high and...

  • Page 41: Digital Display Messages

    Troubleshooting Digital Display Messages LED Status SPRAYER OPERATION INDICATION ACTION Red LED Power is applied. (Pressure Normal operation. Spray varies with tip size and 1 blink at power up pressure control setting). Red LED Sprayer won’t run. Pump won’t cycle. Ensure there is no resistor at J8/2 near the center of the pump control board.

  • Page 42: Parts Drawing

    Parts Drawing Parts Drawing 25M230 86 150 ti30528a 3A4558F Repair, Parts...

  • Page 43: Parts List - 25M230

    278723 GASKET, pail 114682 SPRING, compression 17P224 CAP, leg 108471 KNOB, pronged 100731 WASHER 15E748 BRACKET, manifold 17N701 LABEL, BS 3500SP 287682 LEVER, caster, includes 26 144 194126 LABEL, warning 25P374 ENGINE, gasoline, 6.5 hp 150 16P136 LABEL, safety, warning 129777 REGULATOR 111025 GASKET, polypropylene 867670 FLUID, TSO, 6 oz.

  • Page 44: Parts Drawing

    Parts Drawing Parts Drawing Self-Propelled Drive - Series A ti30602a 3A4558F Repair, Parts...

  • Page 45: Parts List - Self-Propelled Drive - Series A

    Parts List - Self-Propelled Drive - Series A Parts List - Self-Propelled Drive - Series A Ref. Part Description Ref. Part Description 120229 SCREW, hex, flange 17N475 AXLE, self-propelled 17P355 BRACE, motor bracket, painted 17N316 SPACER, unthreaded 129466 CHAIN, roller, #40 17N662 BRACKET, axle 17P356 BRACKET, chain guard 129437 BEARING, flange, 2 bolt...

  • Page 46: Parts Drawing

    Parts Drawing Parts Drawing Self-Propelled Drive - Series B ti33932a 3A4558F Repair, Parts...

  • Page 47: Parts List - Self-Propelled Drive - Series B

    Parts List - Self-Propelled Drive - Series B Parts List - Self-Propelled Drive - Series B Ref. Part Description Ref. Part Description 19A403 SPROCKET, #40, 16T 17N475 AXLE, self-propelled 120229 SCREW, hex, flange 17N316 SPACER, unthreaded 17P355 BRACE, motor bracket, painted 17N662 BRACKET, axle 129466 CHAIN, roller, #40 129437 BEARING, flange, 2 bolt...

  • Page 48: Parts Drawing

    Parts Drawing Parts Drawing 44ref 130ref ti30132a 3A4558F Repair, Parts...

  • Page 49: Parts List - 25M230

    183401 KEY, parallel 140† 16X071 TUBE, drain 193680 COLLAR, shaft 196181 FITTING, nipple 193673 ARMATURE, clutch, 4 in. 17N700 LABEL, pump, BS 3500SP HUB, armature 112395 SCREW, cap, flng hd ROTOR, clutch, 4 in. 146 290228 LABEL, warning 101682 SCREW, cap, sch 17M310 HOUSING, drive, includes 32, 34 ...

  • Page 50: Parts Drawing And List - Pinion Housing

    Parts Drawing and List - Pinion Housing Parts Drawing and List - Pinion Housing Ref No. 44: Pinion Housing Ref. Part Description 17R785 HOUSING, pinion, kit 17R793 KIT, repair, coil 105489 44c* 17R788 PINION SHAFT 44d* 113094 RETAINING RING, large 44e* 165295 O-RING, packing * May be ordered separately...

  • Page 51: Gun Arm Parts

    Gun Arm Parts Gun Arm Parts 72ref ti30135a Part Description Part Description 15E992 CABLE, gun 25M223 GUN, SureStripe 126111 RETAINER, CirClip, external, 8mm 15F216 HOLDER, gun 113428 SCREW, cap, socket, flthd 20a* 15F750 HOLDER, gun, knob 188135 GUIDE, cable 20b* 15F214 LEVER, actuator 69319ST TIP, spray, striping 20c* 15F209...

  • Page 52: Pressure Control/Filter Assembly

    Pressure Control/Filter Assembly Pressure Control/Filter Assembly 62f 62e 361 332 ref. 74 ref. 59 ti30520a ref 13 141ref 118ref 18ref 75ref ti30134a 3A4558F Repair, Parts...

  • Page 53: Parts List - Pressure Control/Filter Assembly

    Parts List - Pressure Control/Filter Assembly Parts List - Pressure Control/Filter Assembly Part Description Part Description 101550 SCREW, cap, sch 108538 SCREW, cap, flat hd 237686 WIRE, ground, assembly w/ 194310 LEVER, actuator clamp 24Z793 COVER, control box, assy 15F928 BUSHING, strain relief 17N544 COVER, control box...

  • Page 54: Pressure Control Wiring Diagram

    Pressure Control Wiring Diagram Pressure Control Wiring Diagram ENGINE REGULATOR SPEED DRIVE ON/OFF 324ref RECTIFIER (129777) JUMPER CONTROL ENGINE KILL ADAPTER BLACK YELLOW YELLOW BLACK BLACK GREEN FUSE BATTERY ORANGE BLACK — MOTOR FRAME RED + CONTROL BOARD CONTROL BOARD WHITE WHITE DARK...

  • Page 55: Drive Control Wiring Diagram

    Drive Control Wiring Diagram Drive Control Wiring Diagram ENGINE REGULATOR SPEED DRIVE ON/OFF RECTIFIER CONTROL ENGINE KILL (129777) FUSE BLACK GREEN BLACK ORANGE BATTERY MOTOR FRAME CONTROL BOARD DRIVE MOTOR BLACK WHITE WHITE BLUE DARK GRAY CRUISE-NEUTRAL-DRIVE SWITCH ti30659a 3A4558F Repair, Parts...

  • Page 56: Pioneer Limited Warranty

    PIONEER LIMITED WARRANTY PIONEER warrants the Brite Striper 3500SP manufactured by it to be free from defects in material and workmanship on the date of sale by an authorized PIONEER Distributor to the original purchaser. Pioneer will, for the period of two (2) years from the date of sale, repair or replace any part of the equipment proven defective.

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