Zodiac Polaris 3900 Sport User manual

1
3900 Sport
Tear Down Instructions

2

3
TABLEOFCONTENTS
DISASSEMBLY
BAG SWEEP HOSE REMOVAL.....................................................................4
BOTTOM HOUSING REMOVAL ...................................................................5
WATER MANAGEMENT REMOVAL .............................................................6
WHEEL REMOVAL .........................................................................................7
GEAR BOX ASSEMBLY ................................................................................8
TOP ASSEMBLY ............................................................................................9
DRIVE TRAIN ..................................................................................................10-14
PRODUCT BREAKDOWN ........................................................................................15
COMPONENT PARTS ..............................................................................................16
ASSEMBLY
AXLE ASSEMBLY ..........................................................................................17
GEAR BOX......................................................................................................18
WHEELS & CHAIN..........................................................................................19-21
TOP ASSEMBLY ............................................................................................22
WATER MANAGEMENT ................................................................................23
BOTTOM & SWEEP HOSE ...........................................................................24
BAG & QUICK DISCONNECT.......................................................................25

4
Remove Sweep hose by
twisting nut to release from
hose
Remove bag by twisting collar
Press logo buttons to remove
Quick Disconnect
BAG AND SWEEP HOSE REMOVAL

5
Remove 3 screws from bottom
of cleaner
Remove Bottom Housing
BOTTOMHOUSINGREMOVAL
Locate3screwslabeled“A” and
remove.

6
RemoveWatermanagement
Systemand Rear Housing
Locate 4 screws labeled “B” and
remove
RemoveGearboxandsingle side
wheel
GEAR BOX REMOVAL

7
Pryhubcap withflat-bladescrew-
driverfor removal
Un-threadscrew toremovewheel
Pullwheel fromgearboxshaft
GEAR BOX REMOVAL

8
GearboxAssembly Part #39-200
GEARBOXCOMPONENTS
Notes:

9
Locateand remove 2 screws
inorderto remove theTop.
RemoveTop
TopAssemblyPart #39-003,
includesfloat.
TOPASSEMBLY REMOVAL

10
Pryhubcap off double-side
wheelswith flat-bladescrew
driver
Un-threadscrew toremove
wheel.
Removewheel.
DRIVETRAINREMOVAL

11
Removewheel sprocket
covertoexpose chain
Removechain fromrearwheel
sprocket
RemoveSprocketandnote
bearingplacement
DRIVETRAINREMOVAL

12
Pressbearingout with screw-
driverandinspect
Reinstallbearing with open face
intoSprocket
Press against closed face of
bearing
DRIVETRAINREMOVAL

13
SprocketAssemblesand chain
Drivetrain
Locateandremove wheel spac-
ersfrom2wheelsideaxles
Locate and remove 2 screws at
the base of the feed pipe
DRIVETRAINREMOVAL

14
RemovetheVacuumTube/
Feed pipe assembly.
Locateandremovethe2
screwsthat attacheachaxle
tothe frame.
Frameassembly with Chain
tensioner.
DRIVETRAINREMOVAL

15
ProductBreakdown COMPONENTS
Notes:

16
PARTNUMBERS

17
Assembleaxleblocks with star
washersand screws.
Turnframeupsidedownand
installaxle blocks toframe.
Brass
Inserts
Brass
Inserts
Dropgearboxintoplacewith
brassinsertspointing up.
ASSEMBLY

18
Attachgearboxwith 4 screws
in pockets labeled “B”.
Installwheel spacersondouble
sidewheelaxle blocks.
AttachVacuum tube/Feed pipe
Assemblytoframe with 3
screws.
ASSEMBLY

19
InstallWheelSprocketson
doublesideaxle.
Wrapchain aroundfrontaxle
sprocketand throughtensioner
asshown.
ASSEMBLY

20
Usethediagramon the
Vacuumtube to assist with
wrapconfiguration.
Installthe 2sprocketcovers.
Locatedouble side wheel
notingone bearing in theouter
cavityof eachwheel.
ASSEMBLY