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.
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O
I
O
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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
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Displacement Pump
3A4558F Repair, Parts 11
Installation
1. Pull piston rod out distance shown. Screw in pump
until holes in connecting rod and piston rod align.
2. Push pin (31) into hole. Push retaining ring spring
into groove all the way around connecting rod.
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
75 ±5 ft-lb (102 N·m). Connect hose (118) and
suction hose (57).
4. Fill packing nut with TSO until fluid flows onto the
top of seal. Install pump rod cover (107).
If pin works loose, parts could break off due to force
of pumping action. Parts could project through the air
and result in serious injury or property damage. Make
sure pin and retaining spring are properly installed.
NOTICE
If the pump jam nut loosens during operation, the
threads of the bearing housing and drive train will be
damaged. Tighten jam nut as specified.
ti30163a
28
31
ti30130b
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Drive Housing and Connecting Rod
12 3A4558F Repair, Parts
Drive Housing and Connecting Rod
Removal
1. Perform Pressure Relief Procedure, page 6.
2. Remove screws (32) and front cover (52).
3. Remove pump. Refer to Displacement Pump,
page 10.
4. Remove four screws (34) from drive housing (43).
5. Pull connecting rod (29) and lightly tap lower rear of
drive housing (43) with plastic mallet to loosen from
pinion housing (44). Pull drive housing and
connecting rod assembly off pinion housing.
6. Inspect crank (47) and connecting rod (29) for
excessive wear and replace parts as needed.
Installation
1. Evenly lubricate inside of bronze bearing (C) in drive
housing (43) with high-quality motor oil. Liberally
pack top roller bearing (E), lower bearing (D) inside
connecting rod (29) with bearing grease.
2. Assemble connecting rod (29) to drive housing (43).
Rotate connecting rod to lowest position.
3. Apply grease to washers 46, 49 and 48. Install in
order shown.
4. Lubricate gears with 0.26 pint of 110293 grease
(supplied with drive housing). Pack grease evenly
around gears.
5. Clean mating surfaces of pinion and drive housings.
6. Align connecting rod with crank (47) and carefully
align locating pins in drive housing (43) with holes in
pinion housing (44). Push drive housing onto pinion
housing or tap into place with plastic mallet.
7. Install screws (34) in drive housing. Torque evenly to
note 3 value.
8. Install pump. Refer to Displacement Pump , page 10.
9. Install front cover (52) with two screws (32).
NOTICE
Thrust washers may stick to grease inside of drive hous-
ing. Do not lose or misplace.
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.
44
46 49
47 48
43
C
E
D
34
52
32
107
29
28
30
27
33
136
57
31
141
32
118
ti30158a
Oil
Pack with bearing grease 110293
Torque to 130-150 in-lb (14-16.9 N•m)
1
2
3
1
3
2
46
49
47
48
ti30410a
Oil
Pack with bearing grease 110293
1
2
2
1

Pinion Assembly/Clutch Armature/Clamp
3A4558F Repair, Parts 13
Pinion Assembly/Clutch Armature/Clamp
Pinion Assembly/Clutch
Armature Removal
Pinion Assembly
If pinion assembly (44) is not removed from clutch
housing (45), do 1. through 3. Otherwise, start at 4.
1. Remove drive housing. Refer to Drive Housing
and Connecting Rod, page 12.
2. Disconnect clutch (+) and clutch (-) connectors from
wire harness located under sprayer cart.
3. Remove four screws (34) and pinion assembly (44).
4. Place pinion assembly (44) on bench with rotor side
up.
5. Remove four screws (42) and lock washers (35).
Install two screws in threaded holes (E) in rotor.
Alternately tighten screws until rotor comes off.
6. Remove retaining ring (44d).
7. Turn pinion assembly over and tap pinion shaft
(44c) out with plastic mallet.
34
35
34
35
44
ti5480a
45
ti5987b
E
E
42
35
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44d
44c
44e

Pinion Assembly/Clutch Armature/Clamp
14 3A4558F Repair, Parts
Clutch Armature
8. Use an impact wrench or wedge something
between clutch armature (39) and clutch housing to
hold engine shaft during removal.
9. Remove four screws (36) and lock washers (35).
10. Remove armature (39).
Installation
Clutch Armature
1. Lay two stacks of two dimes on smooth bench
surface.
2. Lay armature (39) on two stacks of dimes.
3. Press center of hub (40) down to bench surface.
4. Install armature (39) on engine drive shaft.
5. Install four screws (36) and lock washers (35) with
torque of 125 in-lb.
Pinion Assembly
1. Check o-ring (44e) and replace if missing or
damaged.
2. Tap pinion shaft (44c) in with plastic mallet.
3. Install retaining ring (44d) with beveled side facing
up.
4. Place pinion assembly on bench with rotor side up.
5. Apply blue thread locking liquid to screws. Install
four screws (42) and lock washers (35). Alternately
torque screws to 125 in-lb until rotor is secure. Use
threaded holes to hold rotor.
6. Install pinion assembly (44) with four screws (34)
and washers (35).
7. Connect clutch cable connectors to inside of
pressure control.
36
35
39
ti5483a
0.12+01 in (3.0+.25 mm)
39 40
dimes
ti6321a

Pinion Assembly/Clutch Armature/Clamp
3A4558F Repair, Parts 15
Clamp Removal
1. Remove engine. See Engine Removal, page 17.
2. Drain gasoline from tank according to Briggs &
Stratton manual.
3. Tip engine on side so gas tank is down and air
cleaner is up.
4. Loosen two screws (36) on clamp (38).
5. Push screwdriver into slot in clamp (38) and remove
clamp.
Clamp Installation
1. Install engine shaft key (37).
2. Tap clamp (38) onto engine shaft (A). Maintain
dimension shown note 2. Chamfer must face
engine.
3. Check dimension: Place rigid, straight steel bar (B)
across face of clutch housing (45). Use accurate
measuring device to measure distance between bar
and face of clamp. Adjust clamp as necessary.
Torque two screws (36) to 125 ±10 in-lb (14 ±1.1
N•m).
ti29235a
4
3
2
1
ti29237a
Face of clutch housing
1.550 ± .010 in.
(39.37 ± .25 mm)
Torque to 125 ± 10 in-lb
(14 ±1.1 N•m)
Chamfer this side
1
2
3
4
B
A
35,36
45
5
38
37
37

Clutch Housing
16 3A4558F Repair, Parts
Clutch Housing
Removal
1. Remove clamp. Perform Clamp Removal, page 15.
2. Remove four screws (51) and lock washers (50) that
hold clutch housing (45) to engine.
3. Remove screw (145) from under mounting plate.
4. Pull off clutch housing (45).
Installation
1. Push on clutch housing (45).
2. Install four cap screws (51) and lock washers (50)
and secure clutch housing (45) to engine. Torque to
200 in-lb (22.6 N•m).
3. Install screw (145) from beneath mounting plate.
Torque to 26 ft-lb (35.2 N•m).
45
51 50
145 ti30125a

Engine
3A4558F Repair, Parts 17
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. Lift engine carefully and place on work bench.
4. Perform Clamp Removal, page 15, and Clutch
Housing Removal, page 16.
Installation
1. Lift engine carefully and place on cart.
2. Install two screws (110) in base of engine and
secure with lock nuts (111). Torque to 20 ft-lb (27.12
N•m),
3. Connect all necessary wiring.
4. Install Clutch Housing, page 16, and Pinion
Assembly/Clutch Armature/Clamp, page 13.
GROUND
GREEN/YELOW
ON/OFF SWITCH
POTENTIOMETER
CONTROL BOARD
TRANSDUCER
FROM CLUTCH
HOUSING
BLACK
PINK
CLUTCH
RED
CLUTCH
BLACK
66
REF 155
FROM CLUTCH
HOUSING
RED
GREEN/YELLOW
YELLOW/
GREEN
324ref
JUMPER
ADAPTER
324ref
JUMPER
ADAPTER
ti30126b
FROM
ENGINE
(BLACK)
PINK
BLACK
RED
FROM ENGINE
(BLACK)
110
111
ti30124a

Pressure Control Transducer
18 3A4558F Repair, Parts
Pressure Control Transducer
Removal
1. Remove two screws (32) and open cover (62a).
2. Disconnect transducer (155) cable from control
board (62e).
3. Pull transducer connector through strain relief
bushing (151).
4. Remove transducer and o-ring (99) from filter
housing (67).
Installation
1. Install o-ring (99) and transducer (155) in filter hous-
ing (67). Torque to 35 - 45 ft-lb.
2. Install transducer connector and strain relief bush-
ing in control housing.
3. Connect cable (155) to control board (62e).
4. Close cover (62a) and secure with two screws (32).

Pressure Control (On/Off Switch)
3A4558F Repair, Parts 19
Pressure Control (On/Off Switch)
Removal
1. Remove two screws (32) and open cover (62a).
2. Disconnect ON/OFF switch connector from pres-
sure control board (342).
3. Press in on two retaining tabs on each side of
ON/OFF switch (62d) and remove switch from
cover.
Installation
1. Install new ON/OFF switch (62d) so tabs of switch
snap into place on inside of cover.
2. Connect ON/OFF switch connector (B) to pressure
control board.
3. Close cover (62a) and secure with two screws (32).
32
62n
62m
62k
62e
62h
62d
62c
62b
62j
62b
62p
342
62f 62e
62g
62a
62
129
350
B
350
348
333
361 332
151
340
68
184
148
319
183
ref. 74
ref. 59
94
53
362
170
ti30520a
25
364
363
365
366
367
375

Pressure Adjust Potentiometer
20 3A4558F Repair, Parts
Pressure Adjust Potentiometer
Removal
1. Remove two screws (32) and open cover (62a).
2. Disconnect potentiometer (62b) cable from control
board (62e).
3. Loosen set screws on potentiometer knob (62c) and
remove knob, shaft nut, lock washer and
potentiometer (62b).
4. Remove spacer (62g) from potentiometer.
Installation
1. Install spacer (62g) on potentiometer (62b).
2. Install potentiometer, shaft nut, lock washer and
potentiometer knob (62c).
a. Turn potentiometer shaft clockwise to internal
stop. Assemble potentiometer knob (62c) to
touch pin on cover (62a).
b. After adjustment of step a., tighten both set
screws in knob 1/4 to 3/8 turn after contact with
shaft.
3. Connect potentiometer (62b) cable to control board
(62e).
4. Close cover (62a) and secure with two screws (32).
Control Board
Removal
1. Remove two screws (32) and open cover (62a).
2. Disconnect engine wires from wire harness (66).
3. Disconnect at control board (62e):
• Cable from potentiometer (62b)
• Cable from transducer (155)
• Cable from ON/OFF switch (62d)
• Clutch wires
4. Remove four screws (350) and control board (342).
Installation
1. Install control board (342) with four screws (350).
2. Connect at control board (342):
• Clutch wires
• Cable from ON/OFF switch (62d)
• Cable from transducer (155)
• Cable from potentiometer (62b)
3. Connect engine wires.
4. Close cover (62a) and secure with two screws (32).