Minuteman PowerBoss 3800 Service Manual

Model: 383500

®

PowerBoss

3800 Rider
Sweep System Plus

OPERATION SERVICE PARTS CARE

Revised 2/02

TABLE OF CONTENTS

Safety Instructions...........................................1

Installation Instructions......................................2

Removal Instructions ........................................2

Operation.........................................................3

Main Broom Adjustment...................................3

Main Broom Replacement ...............................4

Side Broom Adjustment ...................................5

Side Broom Replacement................................5

Filter Replacement...........................................5

Filter Cleaning .................................................5

Components ............................................6, 7, 8

Main Assembly .................................... 9, 10, 1 1

Hopper Track.................................................12

Main Broom Assembly ...................................14

Side Broom ...................................................15

Chart .............................................................16

Side Cover ..............................................17, 18

Wiring Diagrams......................................19, 20

IMPORTANT SAFETY INSTRUCTIONS

CAUTION:

Operators must read and understand this manual before operating or maintaining this machine.
Disconnect wiring harnesses between 3800 and Sweep System Plus before disconnecting

Sweep System Plus from 3800.
Press Red Emergency Disconnect Button before installing/removing Sweep System Plus

from 3800.
Press Red Emergency Disconnect Button before changing brooms on Sweep System Plus.
All covers and doors must be closed before use.
Keep hands and feet clear of moving parts while machine is in operation.
Disconnect the power to the machine by pressing the Red Emergency Disconnect Button when

charging batteries or during installation or removal of pads.
During operation, loose objects on the floor can become dangerous projectiles if struck by the

high speed brooms. S pecial attention should be paid in removing or avoiding loose floor tile,
electrical cables, and telephone connection boxes.

During operation, attention should be paid to other persons in the work area, especially small
children.

Electrical motors and components can cause an explosion when operated near explosive
materials or vapors. Do not operate this machine near flammable materials such as solvents,
thinners, fuels, grain dust, etc.

Make sure the Red Emergency Disconnect Button is pressed and the battery connector is
unplugged from the machine before performing any service or maintenance procedures.

Store or p ark this machine on a level surface only , with parking brake engaged. T o prevent
unauthorized use, machine should be stored with key removed.

These machines are designed for level floor operation only . Do not operate on ramps

or inclines.

This machine is not suitable for picking up hazardous dusts.
Use caution when moving this machine into areas that are below freezing. Any water in the t anks

or hoses can cause damage.
Do not clean machine with a pressure washer.
Battery acid can cause burns. When working on or around batteries, wear protective clothing and

safety glasses. Remove metal jewelry . Do not lay tools or metal objects on top of batteries.
Charging batteries generates explosive gases. DO NOT CHARGE BA TTERIES WHEN OPEN

FLAMES OR SP ARKS ARE PRESENT. DO NOT SMOKE. Make sure the charger is turned off
before disconnecting it from the machine. Charge the batteries in a well-ventilated area with the
battery cover removed completely .

Authorized personnel must perform maintenance and repairs.

SAVE THESE INSTRUCTIONS

1

INSTALLATION INSTRUCTIONS

1. Depress Red Emergency Disconnect Switch on 3800 Rider.

2. Remove Sweep System Plus from pallet (Fig. 1).

3. Remove hitch pins (Fig. 2).

4. Remove corner rollers from 3800 Rider.

5. Roll Sweeper into position at front of 3800 Rider (Fig. 2). (Be sure not to pinch the
electrical cables).

6. Attach Sweeper to 3800 Rider using hitch pins (Fig. 2).

7. Remove Sweeper carts (Fig. 3). Attach carts together and store (Fig. 4).

8. Electrical Connection: Connect power and circular connectors from Sweeper to the
mating connectors under the main machine.

REMOVAL INSTRUCTIONS

1. Turn Sweeper power “on”. When Sweeper is fully down, move switch to neutral position
(see “OPERA TION” section).

2. Depress Red Emergency Disconnect Switch on 3800 Rider.

3. Electrical Disconnection: Disconnect power & circular connectors under the main machine.

4. Attach carts to left and right side of machine using (4) bolts provided (Fig. 3).

5. Remove hitch pins.

6. Roll Sweeper away from 3800 Rider.

7. Re-attach corner rollers using hitch pins.

2

OPERATION

TO SWEEP:

1. Turn on 3800 Rider power .

2. Move “Presweep Switch” (in operator compartment) to down position.

3. Drive machine.

TO STOP SWEEPING:

1. Move “Presweep Switch” to up position.

2. Allow filter shaker to finish before turning off 3800 Rider power .

TO EMPTY HOPPER:

1. Move “Presweep Switch” to down position.

2. After Sweeper pivots down, move “Presweep Switch” to neutral (middle) position.

3. Depress Red Emergency Disconnect Switch on 3800 Rider.

4. Pull hopper from front of machine using finger hold on bottom of hopper.

MAIN BROOM ADJUSTMENT (Fig. 5)

BROOM HOPPER ADJUSTMENT IS PERFORMED AS FOLLOWS:

1. Remove hopper.

2. Tighten bottom nut to lower brush and tighten upper nut to raise broom.

3. Replace hopper.

Broom should be in contact with the floor when deployed. When pre-sweep
is raised, broom should not be in contact with the floor .

3

MAIN BROOM REPLACEMENT

1. Depress Red Emergency Disconnect Switch on 3800 Rider.

2. Open left hand side door and remove wing nuts (Fig. 6).

3. Remove broom-mounting plate and pull out broom (Fig. 7).

4. Install new broom. Make sure notched side is inserted first. Notches must be placed over
pins in drive side hub (Fig. 8).

5. Re-install broom-mounting plate. Be sure to insert rotating hub into broom cylinder (Fig. 6).

6. Close and latch left hand side door.

SIDE BROOM ADJUSTMENT

The side broom height may be adjusted at either the attachment point on the mainframe or the
motor shaft. The side broom pitch is fixed.

ADJUSTMENT @ MAINFRAME (Fig. 9)

1. Loosen (4) attachment bolts inside mainframe.

2. Raise or lower broom to desired height.

3. Retighten bolts.

ADJUSTMENT @ MOTOR SHAFT (Fig. 10)

1. Remove rue ring and clevis pin.

2. Reposition broom to desired shaft setting.

3. Re-insert clevis pin and rue ring.

4

SIDE BROOM REPLACEMENT (Fig. 10)

1. Remove rue ring.

2. Slide out clevis pin.

3. Slide broom off of shaft.

4. Replace broom, re-insert clevis pin and rue ring.

FILTER REPLACEMENT

1. Remove lid.

2. Remove filter and replace with new filter (NOTE: Air flow direction is up).

3. Replace lid.

FILTER CLEANING

Clean panel filter according to the instructions on the panel filter (see below):

- Clean filter by one of these methods -

Tapping

Tap gently on flat surface ­dirty side down

Air

Direct compressed air
thru panel opposite the
direction

1. Soak 15 min. in water and D1400*

2. Rinse until clean
(max. pressure 40 PSI).

3. Air dry - do not use compressed air.
*Donaldson D1400 element cleaner.

Water

5

6

FIG 5

7

8910

383500 MAIN ASSEMBLY

Item Part No. Qty. Description

1 383502 1 Lid, 3800 Presweep
2 383503 1 Filter Assy.
3 383505 1 Gasket, Dust Duct
4 383507 1 Fan/Fan Housing Assy.
5 383508 1 Hose, Dust Control
6 383511 1 Presweep Mainframe Weldment
7 383524 2 Hinge Pin
8 383525 1 Presweep Mtg. Frame
9 383535 2 Hitch Pin Wmt.

10 383540 1 Hopper Assy .

11 383560 1 Main Broom Arm Assy.
12 383596 1 Pulley, “L” Timing, 20 Tooth
13 383601 1 Stabdard Broom, Proex & Wire
14 383602 1 Optional Broom, Proex
15 383603 1 Optional Broom, Nylon
16 383610 1 Hose Mtg. Wmt.
17 383615 3 Standoff, Duct
18 383616 1 Seal Attachment Plate
19 383617 1 Intake Ring Wmt.
20 383620 1 Intake Duct
21 383621 2 Retainer, Bottom
22 383625 1 Hopper Track Assy. LH
23 383630 1 Hopper Track Assy, RH
24 383635 1 Side Broom Assy.
25 383655 1 Side Cover Assy., LH
26 383660 1 Side Cover Assy., RH
27 383677 2 Cart Assy .
28 383678 1 Mounting Plate
29 383679 2 Mounting Bracket
30 383683 1 Seal, Duct Front/Back
31 383684 2 Seal, Duct Side
32 383685 1 Seal, Rear
33 383686 1 Seal, Duct Front/Back
34 383688 2 Seal, Compartment
35 383693 2 Retainer, Duct Front/Back
36 383694 2 Retainer, Duct Side

Item Part No. Qty. Description

37 383695 1 Retainer Back
38 383700 1 Lid Screen
39 383701 1 Broom Stop Weldment
40 383710 1 Rod-Threaded 3/8-16 x 2 1/2
41 450207 4 Flex Latch
42 711160 8 #10 x 5/8 Hi-Lo
43 711373 9 Nut, Hex 1/4-20 Nyloc ZP
44 711374 6 Nut-Nloc x 5/16-18
45 711425 10 Nut, Hex 1/4-20 Wiznut
46 711544 6 WSR-Helical 1/4
47 711575 6 WSR-Flat .31 x .75 x .06ST
48 712083 8 Bolt Flgd Wizz Loc 3/8-16
49 712103 1 Clevis Pin, 3/8 x 3
50 712537 6 10-24 .75 SS Truss Hd. SCR
51 712575 6 BLT-HH 5/16-18 - .75
52 741200 1 Timer
53 741300 2 Terminal Block
54 742702 1 Motor
55 742712 1 Actuator, Brush 3800 Rider
56 743031 1 Switch, DPDT
57 808744 2 Hose Clamp
58 3305001 1 Shaker Assy.
59 3315204 3 Solenoid
60 3400032 8 SCR-Hex 3/8 - 16 x .75 ZP
61 3400035 4 Bolt-HH 5/16-18 x 1
62 3400036 4 Bolt-HH 5/16-18 x 3/4
63 3400043 10 Bolt-HH 1/4-20 x 1/2 Gr 5
64 340070 4 Nut, Hex 5/16-18 ZP
65 3400071 6 Nut, Hex 1/4-20
66 3400087 2 3/8 Flat WSR
67 3400088 12 5/16 Flat WSR
68 3400102 8 5/16 Lock WSR
69 3400125 2 Rue Ring - 1/4 Heavy ZP
70 3400266 1 Clevis Pin, 3/8 x 2
71 3400338 2 Nut 3/8-16 SS

(Additional 383500 Figures on Page 11.)

383500

MAIN ASSEMBLY

11

383625 HOPPER TRACK ASSY LH

Item Part No. Qty. Description

1 383626 1 Hopper Track Wmt. LH
2 383629 1 Sleeve Bearing, 3/8 ID x 5/8 0D
3 3322190 1 Insert 5/16-18 UNC
4 3400943 1 Shoulder Bolt ½ - ½

383630 HOPPER TRACK ASSY RH

Item Part No. Qty. Description

1 383629 1 Sleeve Bearing, 3/8 ID x 5/8 OD
2 383631 1 Hopper Track Wmt. RH
3 3322190 1 Insert 5/16-18 UNC
4 3400943 1 Shoulder Bolt ½ - ½

12

383540 HOPPER ASSEMBLY

Item Part No. Qty. Description

1 383501 1 Hopper, 3800 Presweep
2 383541 1 Handle, Nielsen 945
3 383542 1 Hopper Ramp
4 383543 1 Retainer, Hopper Flap
5 383547 1 Flap, Hopper
6 383548 1 Hopper Seal Attachment Bracket
7 383682 1 Hopper Seal
8 383692 1 Hopper Seal Retainer
9 711160 3 #10 5/8 Hi-Lo

10 711503 3 #10 WSR

11 712537 3 10-24 x .75 SS Truss Hd. SCR
12 712565 1 4 SCR-MC ¼-20 x .63 SS
13 712638 3 Nut, Hex 10-24 Nyloc SS
14 3322188 14 Insert ¼-20 UNC
15 3400816 5 10-24 x .50 SS Truss Hd. SCR

13

383560 MAIN BROOM ASSEMBLY

Item Part No. Qty . Description

1 383561 1 Brush Arm Weldment
2 383571 2 Pivot Block Assy .
3 383573 2 Pivot Link
4 383575 1 Brush Attachment Weldment
5 383578 1 Block, Adjustment
6 383580 1 Brush Bearing Assy. LH
7 383584 1 Brush Bearing Assy. RH
8 383585 1 Reduction Pulley Assy.
9 383593 1 Cutoff

10 383594 2 Wing Bolt, 3/8-16 x 1

11 383595 1 Pulley, “L” Timing 36 Tooth
12 383597 1 Belt, Timing 3/8 62 Groove
13 383598 1 Belt, Timing 3/8 56 Groove
14 383687 1 Overspray Guard
15 383697 1 Overspray Guard Retainer
16 710584 8 SCR-MC ¼-20 x 1.00 STPL Flat Hd.
17 712536 2 10-24 x .75 SS Truss Hd. SCR
18 712815 5 SCR-MC 10-24 x 1.75 STPL
19 3323296 2 Driver, Main Broom TC/I
20 3323859 3 Key 3/8 x 3/8 5/8
21 3400054 2 Set Screw, ¼-20 x .25
22 3400095 5 Washer Flat #10 ZP
23 3400104 5 Washer Lock #10 Split ZP
24 3400738 2 Roll Pin, 3/8 x 1 ¼
25 3400742 2 Rue Ring - ¼ Heavy ZP
26 3400752 2 Clevis Pin, 3/8 x 2 ¼

14

383635 SIDE BROOM ASSY

Item Part No. Qty. Description

1 361221 1 Clevis Pin
2 383645 1 Side Motor Housing Wmt.
3 383649 1 Broom Mount Shaft
4 383650 1 Cover, Housing
5 383703 1 Side Broom Mount Assy.
6 711124 4 Pan Head ST #10 x .37
7 71 1505 4 ¼ WS R
8 711554 7 WSR-Internal Lock ¼ ID
9 742781 1 Motor, Right Angle Gear

10 3322188 4 Insert ¼-20 UNC

11 3322190 4 Insert 5/16-18 UNC
12 3322382 1 Side Broom
13 3400042 7 Bolt-HH ¼-20 x ¾ Gr 5
14 3400742 1 Rue Ring - ¼ Heavy ZP
15 3400812 2 SCR-Set 8-32 x .25 UNC

15

383677 CART ASSEMBLY

Item Part No. Qty. Description

1 383670 1 Cart Weldment
2 430029 2 Caster
3 711439 2 Nut 3/8-16

16

383660 SIDE COVER ASSY RH

Item Part No. Qty. Description

1 383661 1 Side Cover Weldment RH
2 383681 1 Side Seal
3 383690 1 Front Retainer
4 383691 1 Side Retainer
5 712536 5 10-24 x .75 SS Truss Hd. SCR
6 712565 2 SCR-MC ¼-20 x .63 SS
7 712638 5 Nut, Hex 10-24 Nyloc SS
8 3322188 2 Insert ¼-20 UNC
9 383680 1 Front Seal - LH

17

383655 SIDE COVER ASSY LH

Item Part No. Qty. Description

1 383656 1 Side Cover Assy., Fixed, LH
2 383657 1 Side Door, LH
3 383680 1 Front Seal, LH
4 383681 1 Side Seal
5 383690 1 Front Retainer
6 383691 1 Side Retainer
7 712536 5 10-24 x .75 SS Truss Hd. SCR
8 712565 6 SCR-MC ¼-20 x .63 SS
9 712638 5 Nut, Hex 10-24 Nyloc SS

10 712667 2 Nut, Hex ¼-20 Nyloc SS

11 3300380 1 Latch Assy .
12 3322188 4 Insert ¼-20 Unc
13 3323841 1 Hinge

18

3800 RIDER

SWEEPING SYTEM

WIRING DIAGRAM

19

3800 RIDER

SWEEPING SYTEM

WIRING DIAGRAM

20

LIMITED WARRANTY

Minuteman International, Inc. warrants to the original purchaser/user that this product is free from defects in workmanship
and materials under normal use and service for a period of three years from date of purchase. In addition, Minuteman
International, Inc. will, at its option, honor labor warranty claims for the first 12 months from date of sale, provided such claims
are submitted through and approved by factory authorized repair stations. Minuteman International, Inc. will, at its option,
repair or replace without charge, except for transportation costs, parts that fail under normal use and service when operated
and maintained in accordance with the applicable operation and instruction manuals.

This warranty does not apply to normal wear, or to items whose life is dependent on their use and care, such as belts, cords,
switches, hoses, rubber parts, electrical motor components or adjustments. Parts not manufactured by Minuteman International,
Inc. such as engines, batteries, battery chargers, hydraulic pumps, and tires are covered by and subject to the warranties and/
or guarantees of their manufacturers. Please contact Minuteman International, Inc. for procedures in warranty claims against
these manufacturers.

Special warning to purchaser — Use of replacement filters and/or prefilters not manufactured by Minuteman International,
Inc. or its designated licensees, will void all warranties expressed or implied.

A potential health hazard exists without exact original equipment replacement.
All warranteed items become the sole property of Minuteman International, Inc. or its original manufacturer, whichever the

case may be.
Minuteman International, Inc. disclaims any implied warranty, including the warranty of merchantability and the warranty of

fitness for a particular purpose. Minuteman International, Inc. assumes no responsibility for any special, incidental or
consequential damages.

This limited warranty is applicable only in the U.S.A. and Canada, and is extended only to the original user/purchaser of this
product. Customers outside the U.S.A. and Canada should contact their local distributor for export warranty policies. Minuteman
International, Inc. is not responsible for costs or repairs performed by persons other than those specifically authorized by
Minuteman International, Inc. This warranty does not apply to damage from transportation, alterations by unauthorized
persons, misuse or abuse of the equipment, use of non-compatible chemicals, or damage to property, or loss of income due
to malfunctions of the product.

If a difficulty develops with this machine, you should contact the dealer from whom it was purchased.
This warranty gives you specific legal rights, and you may have other rights which vary from state to state. Some states do not

allow the exclusion or limitation of special, incidental or consequential damages, or limitations on how long an implied
warranty lasts, so the above exclusions and limitations may not apply to you.

A Member of the Hako Group of Companies

World Headquarters PowerBoss®

Minuteman International, Inc. 175 Anderson Street
111 South Rohlwing Road Aberdeen, North
Carolina
Addison, Illinois 60101 28315 USA

[phone] [phone]
FAX [phone] FAX [phone]

987615

Printed in U.S.A.