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

9

10
Item Part No. Qty. Description
1 383502 1 Lid, 3800 Presweep
2 383503 1 FilterAssy.
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 CoverAssy., LH
26 383660 1 Side CoverAssy., RH
27 383677 2 CartAssy.
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
(Additional383500 Figureson Page11.)
383500 MAIN ASSEMBLY
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 ShakerAssy.
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

11
383500
MAIN ASSEMBLY

12
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

13
383540 HOPPERASSEMBLY
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 14 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

14
383560 MAIN BROOM ASSEMBLY
Item Part No. Qty. Description
1 383561 1 Brush Arm Weldment
2 383571 2 Pivot BlockAssy.
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

15
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 711505 4 ¼ WSR
8 711554 7 WSR-Internal Lock ¼ ID
9 742781 1 Motor, RightAngle 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

16
383677 CART ASSEMBLY
Item Part No. Qty. Description
1 383670 1 Cart Weldment
2 430029 2 Caster
3 711439 2 Nut 3/8-16

17
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

18
383655 SIDE COVER ASSY LH
Item Part No. Qty. Description
1 383656 1 Side CoverAssy., 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 LatchAssy.
12 3322188 4 Insert ¼-20 Unc
13 3323841 1 Hinge