Pioneer Athletics 3500SP Operating instructions

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
Repair, Parts
Airless Line Striper 3A4558F
EN
ti30376a

Contents
23A4558F Repair, Parts
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Grounding Procedure (For Flammable Materials
Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Front Wheel Alignment: . . . . . . . . . . . . . . . . . . . 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Drive Housing and Connecting Rod . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pinion Assembly/Clutch Armature/Clamp . . . . . 13
Pinion Assembly/Clutch Armature Removal . . . 13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Clamp Removal . . . . . . . . . . . . . . . . . . . . . . . . 15
Clamp Installation . . . . . . . . . . . . . . . . . . . . . . . 15
Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pressure Control Transducer . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pressure Control (On/Off Switch) . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pressure Adjust Potentiometer . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Drive Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Drive Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Drive/Axle Bearings . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Motor Control Board . . . . . . . . . . . . . . . . . . . . . . . 33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fluid Pump Runs Constantly . . . . . . . . . . . . . . . 38
Control Board Malfunction . . . . . . . . . . . . . . . . . 39
Control Board Malfunction (Steps) . . . . . . . . . . 40
Digital Display Messages . . . . . . . . . . . . . . . . . 41
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
25M230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Parts List - 25M230 . . . . . . . . . . . . . . . . . . . . . . . . 43
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Self-Propelled Drive - Series A . . . . . . . . . . . . . 44
Parts List - Self-Propelled Drive - Series A . . . . . 45
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Self-Propelled Drive - Series B . . . . . . . . . . . . . 46
Parts List - Self-Propelled Drive - Series B . . . . . 47
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Parts List - 25M230 . . . . . . . . . . . . . . . . . . . . . . . . 49
Parts Drawing and List - Pinion Housing . . . . . . 50
Gun Arm Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Pressure Control/Filter Assembly . . . . . . . . . . . . 52
Parts List - Pressure Control/Filter Assembly . . 53
Pressure Control Wiring Diagram . . . . . . . . . . . . 54
Drive Control Wiring Diagram . . . . . . . . . . . . . . . . 55
PIONEER LIMITED WARRANTY . . . . . . . . . . . . . . 56

Warnings
3A4558F Repair, Parts 3
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.
SKIN INJECTION HAZARD
High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the event that
injection occurs, get immediate surgical treatment.
• Do not aim the gun at, or spray any person or animal.
• Keep hands and other body parts away from the discharge. For example, do not try to stop leaks with any
part of the body.
• Always use the nozzle tip guard. Do not spray without nozzle tip guard in place.
• Use Graco nozzle tips.
• Use caution when cleaning and changing nozzle tips. In the case where the nozzle tip clogs while spraying,
follow the Pressure Relief Procedure for turning off the unit and relieving the pressure before removing
the nozzle tip to clean.
• Equipment maintains pressure after power is shut off. Do not leave the equipment energized or under pres-
sure while unattended. Follow the Pressure Relief Procedure when the equipment is unattended or not
in use, and before servicing, cleaning, or removing parts.
• Check hoses and parts for signs of damage. Replace any damaged hoses or parts.
• This system is capable of producing 3300 psi. Use Graco replacement parts or accessories that are rated
a minimum of 3300 psi.
• Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly.
• Verify that all connections are secure before operating the unit.
• Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the controls.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent
flowing through the equipment can cause static sparking. To help prevent fire and explosion:
• Use equipment only in well ventilated area.
• Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable and
can ignite or explode if spilled on hot surface.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static sparking).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are
present.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are
anti-static or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment until you
identify and correct the problem.
• Keep a working fire extinguisher in the work area.

Warnings
43A4558F Repair, Parts
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. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your
material, request Safety Data Sheet (SDS) from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s
replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety
hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch, cut, or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow
the Pressure Relief Procedure and disconnect all power sources.
ENTANGLEMENT HAZARD
Rotating parts can cause serious injury.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Do not wear loose clothing, jewelry or long hair while operating equipment.
• Equipment can start without warning. Before checking, moving, or servicing equipment, remove fuse near
battery.
CARBON MONOXIDE HAZARD
Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing carbon monoxide
can cause death.
• Do not operate in an enclosed area.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
• Read SDS to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:
• Do not touch hot fluid or equipment.

Warnings
3A4558F Repair, Parts 5
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.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
CALIFORNIA PROPOSITION 65
• The engine exhaust from this product contains a chemical known to the state of California to cause cancer,
birth defects or other reproductive harm.
• This product contains a chemical known to the State of California to cause cancer, birth defects or other
reproductive harm. Wash hands after handling.

Grounding Procedure (For Flammable Materials Only)
63A4558F Repair, Parts
Grounding Procedure
(For Flammable Materials Only)
1. Position striper so that the tires are not on pave-
ment.
2. Striper is shipped with a grounding clamp. Ground-
ing clap must attach to grounded object. (e.g. metal
sign post).
Pressure Relief Procedure
Follow the Pressure Relief Procedure
whenever you see this symbol.
1. Perform Grounding Procedure if using flammable
materials.
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.
3. Turn pressure to lowest setting. Trigger gun to
relieve pressure.
4. Engage the trigger lock. Turn prime valve down.
5. If you suspect the spray tip or hose is clogged or
that pressure has not been fully relieved:
a. VERY SLOWLY loosen tip guard retaining nut
or hose end coupling to relieve pressure
gradually.
b. Loosen nut or coupling completely.
c. Clear hose or tip obstruction.
This equipment must be grounded to reduce the risk
of static sparking. Static sparking can cause fumes to
ignite or explode. Grounding provides an escape wire
for the electric current.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury
from pressurized fluid, such as skin injection,
splashed fluid and moving parts, follow the Pressure
Relief Procedure whenever sprayer is stopped and
before sprayer is cleaned or checked, and before
equipment is serviced.
ti30387a
ti30388a
I
O
I
O
ti30389a
ti30107a

Maintenance
3A4558F Repair, Parts 7
Maintenance
DAILY: Check hose for wear and damage.
DAILY: Check gun safety for proper operation.
DAILY: Check pressure drain valve for proper
operation.
DAILY: Check and fill the gas tank.
DAILY: Check level of TSO in displacement pump pack-
ing nut. Fill nut, if necessary. Keep TSO in nut to help
prevent fluid buildup on piston rod and premature wear
of packings and pump corrosion.
Engine Maintenance Schedule
FIRST 5 HOURS: Change oil
EVERY 8 HOURS OR DAILY:
• Check engine oil level.
• Clean area around muffler and controls.
• Clean air intake grille.
EVERY 25 HOURS OR ANNUALLY:
• Clean air filter.
• Clean pre-cleaner.
EVERY 50 HOURS OR ANNUALLY:
• Change engine oil.
• Service exhaust system.
EVERY 100 HOURS: Change gear reduction oil (if
equipped)
ANNUALLY:
• Replace spark plug.
• Replace air filter.
• Replace pre-cleaner.
• Service fuel system.
• Service cooling system.
• Check valve clearance.
SPARK PLUG: Use only Briggs & Stratton 491055S or
Champion RC12YC spark plug. Gap plug to 0.030 in.
(0.762mm). Use spark plug wrench when installing and
removing plug.
Front Wheel Alignment:
Align front wheel as follows:
1. Loosen cap screw (114).
2. Position front wheel left or right, as necessary, to
straighten alignment.
3. Tighten cap screw. Push striper and let striper roll
with hands off of striper.
NOTE: If striper veers right or left, repeat steps 1 and 2
until striper rolls straight.
114
ti30295a

Troubleshooting
83A4558F Repair, Parts
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.
Cold engine Use choke
Fuel shutoff / Engine kill switch is OFF Move lever to ON position.
Oil is seeping into combustion chamber Remove spark plug. Pull starter 3 to 4
times. Clean or replace spark plug. Start
engine. Keep sprayer upright to avoid oil
seepage
Engine operates, but displacement pump
does not operate
Pump switch is OFF Turn pump switch ON
Pressure setting too low Turn pressure adjusting knob clockwise to
increase pressure
Fluid filter is dirty Clean filter
Tip or tip filter is clogged Clean tip or tip filter (see gun manual)
Displacement pump piston rod is stuck
due to dried paint
Repair pump (see pump manual)
Connecting rod is worn or damaged See parts manual
Drive housing is worn or damaged See parts manual
Electrical power is not energizing clutch
field
See parts manual
Reference pressure control repair. Pages
18, 19, 20.
Reference wiring diagram. Page 54.
With pump switch ON and pressure turned
to MAXIMUM, use a test light to check for
power between clutch test points on control
board.
Remove clutch wires from control board
and measure resistance across clutch coil.
At 70°F, the resistance must be between
1.2+0.2 ohms; if not, replace pinion
housing
Have pressure control checked by
authorized dealer
Clutch is worn, damaged, or incorrectly
positioned
Adjust or replace clutch. Page 13.
Pinion assembly is worn or damaged Repair or replace pinion assembly. Page
13.

Troubleshooting
3A4558F Repair, Parts 9
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. See pump manual.
Intake valve ball is not seating properly Clean intake valve. See pump manual. See
operations manual.
Intake valve ball is packed with material Clean intake valve. See operations
manual.
Engine speed is too low Increase pressure. See operations
manual.
Clutch is worn or damaged Adjust or replace clutch. Page 13.
Pressure setting is too low Increase pressure. See operations
manual.
Fluid filter, tip filter or tip is clogged or
dirty
Clean filter. See operations manual.
Large pressure drop in hose with heavy
materials
Use larger diameter hose and/or reduce
overall length of hose. Use of more than
100 ft. of 1/4 in. hose significantly reduces
performance of sprayer. Use 3/8 in. hose
for optimum performance (50 ft. minimum)
Excessive paint leakage into throat packing
nut
Throat packing nut is loose Remove throat packing nutspacer. Tighten
throat packing nut just enough to stop
leakage.
Throat packings are worn or damaged Replace packings. See pump manual.
Displacement rod is worn or damaged Replace rod. See pump manual.
Fluid is spitting from gun Air in pump or hose Check and tighten all fluid connections.
Reprime pump. See operations manual.
Tip is partially clogged Clear tip. See gun manual.
Fluid supply is low or empty Refill fluid supply. Prime pump. See
operations manual. Check fluid supply
often to prevent running pump dry.
Pump is difficult to prime Air in pump or hose Check and tighten all fluid connections.
Reduce engine speed and cycle pump as
slowly as possible during priming.
Intake valve is leaking Clean intake valve. Be sure ball seat is not
nicked or worn and that ball seats well.
Reassemble valve.
Pump packings are worn Replace pump packings. See pump
manual.
Paint is too thick Thin the paint according to the supplier’s
recommendations
Engine speed is too high Decrease throttle setting before priming
pump. See operations manual.
Clutch squeaks each time clutch engages Clutch surfaces are not matched to
each other when new and may cause
noise
Clutch surfaces need to wear into each
other. Noise will dissipate after a day of run
time.
High engine speed at no load
(> 3800 rpm)
Worn engine governor Replace or service engine governor
Problem Cause Solution

Displacement Pump
10 3A4558F Repair, Parts
Displacement Pump
Removal
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).
4. Remove hose (118) and suction hose (57). Use
screwdriver; push retaining spring (28) up; push out
pin (31).
5. Loosen jam nut by hitting firmly with a hammer.
Unscrew pump.
Repair
See manual 3A4347 for pump repair instructions.
107
32
ti30159a
31
29
28
118
57
ti30160a
ti30161a