Minuteman PowerBoss 3800 Guide

Model: 383500
PowerBoss®
3800 Rider
Sweep System Plus
OPERATION SERVICE PARTS CARE
Revised2/02

SafetyInstructions...........................................1
InstallationInstructions......................................2
RemovalInstructions ........................................2
Operation.........................................................3
MainBroomAdjustment ...................................3
MainBroom Replacement ...............................4
SideBroomAdjustment ...................................5
Side Broom Replacement................................5
FilterReplacement...........................................5
FilterCleaning .................................................5
Components ............................................ 6, 7, 8
MainAssembly .................................... 9, 10, 11
HopperTrack.................................................12
MainBroomAssembly ...................................14
Side Broom ...................................................15
Chart .............................................................16
Side Cover ..............................................17, 18
Wiring Diagrams......................................19, 20
TABLE OF CONTENTS

1
IMPORTANT SAFETY INSTRUCTIONS
CAUTION:
Operatorsmust read and understandthismanualbefore operating or maintainingthismachine.
Disconnectwiringharnesses between 3800 and Sweep System Plus before disconnecting
SweepSystemPlusfrom3800.
PressRed Emergency Disconnect Buttonbeforeinstalling/removingSweep System Plus
from3800.
PressRed Emergency Disconnect Button before changing brooms on Sweep SystemPlus.
Allcoversanddoorsmustbe closed before use.
Keephandsandfeetclearofmovingpartswhilemachineisin operation.
Disconnectthe power to themachineby pressing the RedEmergencyDisconnectButton when
chargingbatteries or during installation or removal of pads.
Duringoperation,loose objects on the floor can become dangerous projectiles if struck by the
high speed brooms. Special attention should be paid in removing or avoiding loose floor tile,
electricalcables, and telephoneconnectionboxes.
Duringoperation, attention should be paid to other persons in the work area,especiallysmall
children.
Electricalmotors and components can causeanexplosionwhen operated near explosive
materialsor vapors. Do not operate this machine near flammable materials suchassolvents,
thinners,fuels,graindust,etc.
Makesure the Red Emergency Disconnect Button is pressed and the batteryconnectoris
unpluggedfrom the machinebeforeperformingany service ormaintenanceprocedures.
Storeorparkthismachineonalevelsurfaceonly,withparkingbrakeengaged. To prevent
unauthorizeduse, machineshouldbe storedwithkey removed.
These machines are designed for level floor operation only. Do not operate on ramps
or inclines.
Thismachine is not suitable forpickinguphazardousdusts.
Usecaution when moving thismachineintoareas that are below freezing. Anywaterinthe tanks
or hoses can cause damage.
Donot clean machine withapressurewasher.
Batteryacid can cause burns. When working onoraroundbatteries,wear protective clothing and
safetyglasses. Removemetaljewelry. Do not laytoolsormetalobjectson top of batteries.
Chargingbatteriesgeneratesexplosivegases. DONOTCHARGE BATTERIES WHEN OPEN
FLAMES OR SPARKSARE PRESENT. DO NOTSMOKE. Make sure the charger is turned off
beforedisconnecting it from the machine. Charge the batteries inawell-ventilatedareawiththe
batterycover removedcompletely.
Authorizedpersonnel mustperformmaintenanceand repairs.
SAVE THESE INSTRUCTIONS

2
INSTALLATION INSTRUCTIONS
1. Depress Red Emergency Disconnect Switch on 3800 Rider.
2. RemoveSweep System Plus from pallet(Fig.1).
3. Removehitch pins(Fig.2).
4. Removecorner rollersfrom3800Rider.
5. Roll Sweeper into position atfront of 3800 Rider(Fig. 2). (Be sure notto pinch the
electricalcables).
6. Attach Sweeper to 3800 Rider using hitch pins (Fig. 2).
7. RemoveSweepercarts(Fig. 3). Attachcarts together and store (Fig.4).
8. ElectricalConnection: Connectpowerandcircular connectors from Sweeper to the
matingconnectors underthemain machine.
REMOVAL INSTRUCTIONS
1. Turn Sweeper power“on”. WhenSweeper is fully down,moveswitch to neutralposition
(see“OPERATION”section).
2. Depress Red Emergency Disconnect Switch on 3800 Rider.
3. Electrical Disconnection: Disconnectpower&circular connectors under the main machine.
4. Attachcarts to left and right side of machine using(4)boltsprovided(Fig. 3).
5. Removehitch pins.
6. RollSweeper away from 3800 Rider.
7. Re-attachcorner rollersusinghitch pins.

3
OPERATION
TO SWEEP:
1. Turnon 3800Riderpower.
2. Move“Presweep Switch” (inoperatorcompartment)todown position.
3. Drivemachine.
TO STOP SWEEPING:
1. Move“Presweep Switch” to up position.
2. Allowfilter shaker to finish beforeturningoff 3800 Rider power.
TO EMPTY HOPPER:
1. Move“Presweep Switch” to downposition.
2. AfterSweeper pivots down,move“PresweepSwitch”toneutral(middle) position.
3. Depress Red Emergency Disconnect Switch on 3800 Rider.
4. Pullhopper fromfrontof machine using fingerholdonbottom of hopper.
MAIN BROOMADJUSTMENT (Fig. 5)
BROOM HOPPER ADJUSTMENT IS PERFORMED AS FOLLOWS:
1. Removehopper.
2. Tightenbottom nuttolowerbrush andtightenuppernut toraisebroom.
3. Replacehopper.
Broomshould be in contactwiththefloor when deployed. When pre-sweep
israised, broom should not be in contactwith the floor.

4
MAIN BROOM REPLACEMENT
1. Depress Red Emergency Disconnect Switch on 3800 Rider.
2. Openleft hand side door and removewingnuts(Fig.6).
3. Removebroom-mountingplateandpull out broom (Fig.7).
4. Installnewbroom. Makesurenotchedsideisinserted first. Notches must be placed over
pins in drive side hub (Fig. 8).
5. Re-install broom-mountingplate. Besureto insert rotating hub into broomcylinder(Fig.6).
6. Closeand latch lefthand side door.
SIDE BROOM ADJUSTMENT
The sidebroom height may be adjusted at either theattachmentpointonthe mainframe or the
motorshaft. Thesidebroompitchisfixed.
ADJUSTMENT @ MAINFRAME (Fig. 9)
1. Loosen(4) attachmentboltsinsidemainframe.
2. Raise or lower broom to desired height.
3. Retightenbolts.
ADJUSTMENT @ MOTOR SHAFT (Fig. 10)
1. Removerue ringandclevis pin.
2. Repositionbroom to desired shaft setting.
3. Re-insertclevis pinandruering.

5
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):
Tapping
Tap gently on flat surface -
dirty side down
Air
Direct compressed air
thrupanelopposite the
direction
Water
1. Soak 15 min. in water and D1400*
2. Rinseuntilclean
(max.pressure40PSI).
3. Air dry - do not use compressed air.
*DonaldsonD1400elementcleaner.
-Clean filter by one of these methods -

6

7
FIG 5

8