3900 Sport

Tear Down Instructions

TABLE OF CONTENTS
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

BAG AND SWEEP HOSE REMOVAL

Press logo buttons to remove
Quick Disconnect

Remove bag by twisting collar

Remove Sweep hose by

twisting nut to release from
hose

BOTTOM HOUSING REMOVAL

Remove 3 screws from bottom
of cleaner

Remove Bottom Housing

Locate 3 screws labeled A and

remove.

GEAR BOX REMOVAL

Remove Water management
System and Rear Housing

Locate 4 screws labeled B and

remove

Remove Gearbox and single side

wheel

GEAR BOX REMOVAL

Pry hubcap with flat-blade screwdriver for removal

Un-thread screw to remove wheel

Pull wheel from gearbox shaft

GEAR BOX COMPONENTS

Gearbox Assembly Part #39-200

Notes:

TOP ASSEMBLY REMOVAL

Locate and remove 2 screws
in order to remove the Top.

Remove Top

Top Assembly Part #39-003,

includes float.

DRIVE TRAIN REMOVAL

Pry hubcap off double-side
wheels with flat-blade screw
driver

Un-thread screw to remove

wheel.

Remove wheel.

10

DRIVE TRAIN REMOVAL

Remove wheel sprocket
cover to expose chain

Remove chain from rear wheel

sprocket

Remove Sprocket and note

bearing placement

11

DRIVE TRAIN REMOVAL

Press bearing out with screwdriver and inspect

Reinstall bearing with open face

into Sprocket

Press against closed face of

bearing

12

DRIVE TRAIN REMOVAL

Sprocket Assembles and chain

Drivetrain
Locate and remove wheel spacers from 2 wheel side axles

Locate and remove 2 screws at

the base of the feed pipe

13

DRIVE TRAIN REMOVAL

Remove the Vacuum Tube/
Feed pipe assembly.

Locate and remove the 2

screws that attach each axle
to the frame.

Frame assembly with Chain

tensioner.

14

COMPONENTS
Product Breakdown

Notes:

15

PART NUMBERS

16

ASSEMBLY
Assemble axle blocks with star
washers and screws.

Turn frame upside down and

install axle blocks to frame.

Drop gearbox into place with

brass inserts pointing up.

Brass
Inserts

17

ASSEMBLY
Attach gearbox with 4 screws
in pockets labeled B.

Install wheel spacers on double

side wheel axle blocks.

Attach Vacuum tube/Feed pipe

Assembly to frame with 3
screws.

18

ASSEMBLY
Install Wheel Sprockets on
double side axle.

Wrap chain around front axle

sprocket and through tensioner
as shown.

19

ASSEMBLY
Use the diagram on the
Vacuum tube to assist with
wrap configuration.

Install the 2 sprocket covers.

Locate double side wheel

noting one bearing in the outer
cavity of each wheel.

20

ASSEMBLY
Align wheels into sprockets and
attach with locking screw.

Locking screw

Attach single side wheel with

the same locking screw.

21

ASSEMBLY
Replace top assembly with
2 screws.

Inspect o-ring on Water

management System.

Snap rear housing to Water

management System.

22

ASSEMBLY
Attach Water management
System with 3 screws.

Align bottom housing.

23

ASSEMBLY
Attach bottom housing with 3
screws

Snap hub caps on all

wheels.

Attach sweep hose - install

nut first then thread back
onto sweep hose.

24

ASSEMBLY
Note the serial number
location under the canopy.

Press bag into vacuum tube.

Install quick disconnect.

25

Notes:

26

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3900 SPORT TEARDOWN - 2/12

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