Clarke RSW 37 Service Manual
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Clarke RSW 37 Service Manual

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RSW 37
Service Manual
Form No. 1464380000 - 11/2009

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Summary of Contents for Clarke RSW 37

  • Page 1 RSW 37 Service Manual Form No. 1464380000 - 11/2009...
  • Page 2 ENGLISH SERVICE MANUAL 1464380000(1)2009-11 RSW 37...

  • Page 3: Table Of Contents

    FILTER SHAKER MOTOR ELECTRICAL INPUT CHECK .................. 36 TROUBLESHOOTING ............................37 MANUAL VACUUM SYSTEM ..........................38 MANUAL VACUUM SYSTEM MOTOR CARBON BRUSH CHECK AND REPLACEMENT ....... 38 MANUAL VACUUM SYSTEM MOTOR REMOVAL/INSTALLATION ..............39 TROUBLESHOOTING ............................39 RSW 37 1464380000(1)2009-11...
  • Page 4 NON-START FUNCTION CHECK (WITHOUT OPERATOR ON THE DRIVER’S SEAT) ........53 HOOD SAFETY SWITCH OPERATION CHECK ....................53 NON-START FUNCTION CHECK (WITH BATTERY CHARGER CONNECTED TO THE ELECTRICAL MAINS) .......................... 53 COMPONENT LAYOUT ............................54 WIRING DIAGRAM ............................. 57 RSW 37 1464380000(1)2009-11...

  • Page 5: General Information

    – RSW 37 - User Manual – Clarke Form Number 1464352000 – RSW 37 - Manual Vacuum System Kit – Clarke Form Number 146 2049 000 – RSW 37 - Working light Kit – Clarke Form Number 146 2053 000 –...

  • Page 6: General Safety Precautions

    When lead (WET) batteries are installed on the machine, do not tilt the machine more than 30° from the horizontal plane to prevent the highly corrosive acid from leaking out of the batteries. When the machine is to be tilted to perform maintenance procedures, remove the batteries. RSW 37 1464380000(1)2009-11...
  • Page 7 Do not allow to be used as a toy. Close attention is necessary when used near children. – Use only as shown in this Manual. Use only Clarke’s recommended accessories. – Do not lean liquid containers on the machine, use the relevant can holder.

  • Page 8: Technical Data

    Battery capacity 100 – 240 Ah C5 Battery compartment maximum size 14.1x14.8x15.2 in (357x375x385 mm) Dust vacuuming and filtering Values Paper dust filter 5-10 µm 32.3 ft (3 m Main broom compartment vacuum 0.75 inH O (18 mmH RSW 37 1464380000(1)2009-11...

  • Page 9: Dimensions

    SERVICE MANUAL ENGLISH GENERAL INFORMATION DIMENSIONS RSW 37 1464380000(1)2009-11...

  • Page 10: Maintenance

    Main broom driving belt check Nut and screw tightening check Service and parking brake check and adjustment Main broom driving belt replacement Main motor and drive system motor carbon brush check and replacement (1): And after the first 8 running-in hours. RSW 37 1464380000(1)2009-11...

  • Page 11: Machine Nomenclature

    Main broom left lid Main broom height left adjuster Main broom height right adjuster Main broom right lid Main broom right lid mounting screws Pivoting light (always on when the ignition switch is turned to “I” position) (optional) RSW 37 1464380000(1)2009-11...
  • Page 12 ENGLISH SERVICE MANUAL GENERAL INFORMATION MACHINE NOMENCLATURE (continues) S301625 RSW 37 1464380000(1)2009-11...
  • Page 13 SERVICE MANUAL ENGLISH GENERAL INFORMATION MACHINE NOMENCLATURE (continues) 67 66 S301626 RSW 37 1464380000(1)2009-11...

  • Page 14: Sweeping System

    Remove the screws (43) and the right lid (42) together with the belt (71). Install the components in the reverse order of removal. Install the tensioner (92) of the belt (71) as shown in the figure. S300801 RSW 37 1464380000(1)2009-11...

  • Page 15: Main Broom Height Check And Adjustment

    Perform step 1 again to check that the main broom is at the correct distance from the ground. When the broom is too worn and can no longer be adjusted, replace it according to the procedure shown in the following paragraph. S301625 S300803 RSW 37 1464380000(1)2009-11...

  • Page 16: Main Broom Replacement

    Check that the drive hub (I) is free from dirt or foreign materials (cords, rags, etc.) accidentally rolled up. Install the broom lid (D) by engaging the fasteners (E). Screw down the knob (C). Adjust the new broom height according to the procedure shown in the previous paragraph. S300804 S300805 S300806 S300807 S300808 RSW 37 1464380000(1)2009-11...

  • Page 17: Side Broom Height Check And Adjustment

    (G) as necessary; then tighten the locknut (F). When the brooms are too worn and can no longer be adjusted, replace them according to the procedure shown in the relevant paragraph. Perform steps 3 to 8 in the reverse order. RSW 37 1464380000(1)2009-11...
  • Page 18 ENGLISH SERVICE MANUAL SWEEPING SYSTEM SIDE BROOM HEIGHT CHECK AND ADJUSTMENT (continues) S300809 RSW 37 1464380000(1)2009-11...

  • Page 19: Side Broom Replacement

    Install the new broom (H) onto the hub (G), and tighten the screws (F). Fit the key (D) and install the broom with the hub (B). Install the washer (E) and tighten the screw (A). Adjust the side broom height, as described in the previous paragraph. S300529A RSW 37 1464380000(1)2009-11...

  • Page 20: Main Motor Electrical Input Check

    If necessary, remove, clean and check the main motor. If the above-mentioned procedures do not lead to a correct electrical input, the motor must be replaced. Reset Perform steps 4 and 5 in the reverse order. S300811 RSW 37 1464380000(1)2009-11...

  • Page 21: Starter/Dynamo Or Main Motor Carbon Brush Check And Replacement

    Replace the carbon brushes as an assembly. Install the components in the reverse order of removal, and note the following: When connecting the terminals (E), take care of their insulation from the surrounding parts of the frame. S300812 RSW 37 1464380000(1)2009-11...

  • Page 22: Main Motor And Reduction Unit Removal/Installation

    Install the motor/reduction unit (O) with the three screws (M) and the nut (N), use the slots (AC) in order to place the unit (O) and the fan (AA) as close as possible to the machine cover (AB) without touching it. S300813 RSW 37 1464380000(1)2009-11...
  • Page 23 SERVICE MANUAL ENGLISH SWEEPING SYSTEM MAIN MOTOR AND REDUCTION UNIT REMOVAL / INSTALLATION (continues) S300814 RSW 37 1464380000(1)2009-11...

  • Page 24: Starter/Dynamo And Reduction Unit Removal/Installation

    Install the starter/dynamo and reduction unit (O) with the three screws (M) and the nut (N), use the slots (AC) in order to place the unit (O) and the fan (AA) as close as possible to the machine cover (AB) without touching it. B G F S300815 RSW 37 1464380000(1)2009-11...
  • Page 25 SERVICE MANUAL ENGLISH SWEEPING SYSTEM STARTER/DYNAMO AND REDUCTION UNIT REMOVAL/INSTALLATION (continues) S300816 RSW 37 1464380000(1)2009-11...

  • Page 26: Side Broom Motor Electrical Input Check

    If necessary, remove, clean and check the side broom motors. If the above-mentioned procedures do not lead to a correct electrical input, the motor must be replaced. Reset Perform steps 4 and 5 in the reverse order. S300811 RSW 37 1464380000(1)2009-11...

  • Page 27: Side Broom Motor Removal/Installation

    Remove the screw (C). Remove the hub (D) and take out the key (D). Disconnect the connector (F). Remove the screws (G). Remove the side broom motor (H). Install the components in the reverse order of removal. S300818 RSW 37 1464380000(1)2009-11...

  • Page 28: Side Broom Microswitch Adjustment/Replacement

    Disengage the side broom lifting cables (D) from the relevant housings, then remove them. Assembly Assemble the components in the reverse order of disassembly. Adjust the side broom height (see the procedure in the relevant paragraph). S301629 RSW 37 1464380000(1)2009-11...
  • Page 29 If necessary, disconnect the connections (F), remove the screws (A) and replace the microswitch (B). After installing the microswitch (B), adjust it as shown in step 5. Reset Install the front cover (see the procedure in the relevant paragraph). Perform step 2 again. S301630 RSW 37 1464380000(1)2009-11...

  • Page 30: Troubleshooting

    THE MOTORS KEEP RUNNING EVEN IF THE IGNITION KEY IS TURNED TO “0” Possible causes: The electromagnetic switch is faulty (replace). WARNING! In this case, pay careful attention when disconnecting the battery connector (63), because the hood safety system is not operating. RSW 37 1464380000(1)2009-11...

  • Page 31: Skirt

    If necessary, for the front skirt control cable adjustment or replacement, see the following pages. Install the components in the reverse order of removal. S300246 S300247 RSW 37 1464380000(1)2009-11...
  • Page 32 ENGLISH SERVICE MANUAL SKIRT SKIRT HEIGHT AND OPERATION CHECK (continues) S300248 S300249 S300250 S300251 S300376 S300377 RSW 37 1464380000(1)2009-11...

  • Page 33: Side Skirt Replacement

    Remove the screws (G), the strap (H) and the side skirt (I). Install the new skirt (I) with the straps (H) and the screws (G). Adjust the side skirt height as shown in the previous paragraph. Install the components in the reverse order of removal. S300253 S300254 S300255 RSW 37 1464380000(1)2009-11...

  • Page 34: Front And Rear Skirt Replacement

    Install the new skirt (A) and/or (B) with the strap (D) and the screws (C). Adjust the skirt height according to the procedure shown in the relevant paragraph. Install the components in the reverse order of removal. If necessary, for the front skirt control cable adjustment, see the relevant paragraph. S300819 RSW 37 1464380000(1)2009-11...

  • Page 35: Front Skirt Lifting Cable Adjustment

    In order to adjust the front skirt lifting cable (E), loosen the lock nut (C) and turn the terminal (D) as necessary. Tighten the locknut (C). Perform step 4 again to check adjustment. Install the components in the reverse order of removal. S300821 RSW 37 1464380000(1)2009-11...

  • Page 36: Front Skirt Lifting Cable Replacement

    Remove the clip (F) and disconnect the lifting cable terminal (G) from the pedal (H). Remove the front skirt lifting cable (K). Install the components in the reverse order of removal. Adjust the front skirt lifting cable (see the procedure in the previous paragraph). S300822 RSW 37 1464380000(1)2009-11...

  • Page 37: Dust And Debris Collection System

    If necessary, clean the filter compartment rubber seal (G) along its perimeter and check it for integrity. If necessary, replace Install the components in the reverse order of removal. Install the filter with the gauze (E) facing the fan (73). S300823 S300824 RSW 37 1464380000(1)2009-11...

  • Page 38: Filter Shaker Operation Check

    (C) is 3 - 5 A at 24 V. Turn the ignition key (2) to “0”. Remove the ammeter. If the electrical input is higher, the motor must be replaced. Install the hopper (36) as shown in the User Manual. S300259 RSW 37 1464380000(1)2009-11...

  • Page 39: Troubleshooting

    The wiring harness is damaged (repair). The filter shaker motor fuse is blown (replace). There is dust in the filter shaker motor vibrating mass case (remove and clean). The filter shaker motor temperature is excessive (let it cool down and try again). RSW 37 1464380000(1)2009-11...

  • Page 40: Manual Vacuum System

    If necessary, replace the carbon brushes. Replace the carbon brushes as an assembly. Install the components in the reverse order of removal. S301196 RSW 37 1464380000(1)2009-11...

  • Page 41: Manual Vacuum System Motor Removal/Installation

    There are dust or foreign materials preventing the operation of the manual vacuum system (remove). The motor carbon brushes are worn (replace). The motor is faulty (repair or replace). The fuse is blown (replace). The manual vacuum system switch is damaged (replace). The wiring harness is damaged (repair). RSW 37 1464380000(1)2009-11...

  • Page 42: Brake System

    Loosen the locknuts (A) and loosen/tighten the threaded tie rod (B) as necessary. When the adjustment is completed, tighten the locknuts (A). Lower the hoisting system (if available) and remove the machine. Perform hands-on tests to check parking brake and brake operation. S301631 RSW 37 1464380000(1)2009-11...

  • Page 43: Brake Replacement

    Remove the wheel assembly (G) with brake (L). Separate the brake assembly (L) from the wheel (G). Assembly Assemble the components in the reverse order of disassembly. Adjust the brakes (see the procedure in the relevant paragraph). S301633 RSW 37 1464380000(1)2009-11...

  • Page 44: Drive System

    If necessary, remove, clean and check the drive system motor. If the above-mentioned procedures do not lead to a correct electrical input, the motor must be replaced (see the procedure in the relevant paragraph). Reset Perform steps 3 to 5 in the reverse order. S300827 1464380000(1)2009-11 RSW 37...

  • Page 45: Drive System Motor Carbon Brush Check And Replacement

    Replace the carbon brushes as an assembly. Install the components in the reverse order of removal, and note the following: When connecting the terminals (E), take care of their insulation from the surrounding parts of the frame. S300239 RSW 37 1464380000(1)2009-11...

  • Page 46: Drive System Motor Removal/Installation

    Remove the washers (D), the pinion (E), the spacer (F) and take out the key (G). Remove the screws (H) and recover the washers (I). Move the reduction unit (J) and disconnect the connector (K). Install the components in the reverse order of removal. S300828 RSW 37 1464380000(1)2009-11...

  • Page 47: Drive Pedal Check And Adjustment

    After resetting, screw down the threaded dowel (E) locking the potentiometer shaft (K). Perform steps 3 and 4 in the reverse order. Carry out hands-on tests to check the drive pedal operation. The microswitch (H) is no longer provided on this machine after the change dated February 2005. S300829 RSW 37 1464380000(1)2009-11...

  • Page 48: Troubleshooting

    Possible causes: The batteries are discharged (charge). The drive system motor carbon brushes are worn (replace). The drive system motor is faulty (repair/replace). There are foreign materials clogging the front wheel (remove). The wiring harness is damaged (repair). 1464380000(1)2009-11 RSW 37...

  • Page 49: Other Systems

    (as shown in the figure), by setting it down carefully on a proper guard (B). Check for: • Tightening of mounting screws and nuts; • Correct position of the fasteners; • Visible faults in the components; Perform steps 3 and 8 in the reverse order. S300835 RSW 37 1464380000(1)2009-11...

  • Page 50: Front Cover Disassembly/Assembly

    Place the steering wheel (D) with the knob (R) on the left side, with the front wheel (S) in the longitudinal position (not turned), as shown in the figure. Adjust the brakes (see the procedure in the relevant paragraph). Adjust the side broom height (see the procedure in the relevant paragraph). RSW 37 1464380000(1)2009-11...
  • Page 51 SERVICE MANUAL ENGLISH OTHER SYSTEM FRONT COVER DISASSEMBLY/ASSEMBLY (continues) S301635 RSW 37 1464380000(1)2009-11...

  • Page 52: Steering Column Tilting Adjusting Lever Replacement

    STEERING COLUMN TILTING ADJUSTING LEVER REPLACEMENT Disassembly Remove the front cover (see the procedure in the relevant paragraph). Disconnect the steering column tilting adjusting lever (A) from the plunger (B). Assembly Assemble the components in the reverse order of disassembly. S301636 RSW 37 1464380000(1)2009-11...

  • Page 53: Electrical System

    Turn the battery charger selector (69) to WET or GEL according to the type of batteries. Install the batteries on the machine according to the diagram (78), then connect the cables. Connect the battery connector (63). Charge the batteries (see the procedure in the User Manual). S300836 RSW 37 1464380000(1)2009-11...

  • Page 54: Drive System Electronic Board Replacement

    Disconnect the connections (C, D, E, F, G, H, I) from the drive system electronic board (J). Remove the nuts (K), then remove the drive system electronic board (J). Install the new electronic board in the reverse order of removal. S300837 RSW 37 1464380000(1)2009-11...

  • Page 55: Hour Counter And Battery Voltage Display Electronic Board Replacement

    When the machine is off, connect the battery charger cable (65) to the electrical mains. Try to start the machine by turning the ignition key (2) to “I”. The machine should not start. Disconnect the battery charger cable (65) from the electrical mains. RSW 37 1464380000(1)2009-11...

  • Page 56: Component Layout

    Drive speed potentiometer Hood safety switch Emergency push-button Main broom, vacuum fan and filter shaker switch Driver’s seat safety microswitch Forward/reverse gear microswitch Side broom microswitch Drive system switch Manual vacuum system switch (optional) Working light switch RSW 37 1464380000(1)2009-11...
  • Page 57 SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM COMPONENT LAYOUT (continues) 9-33 8-10-11 S300839 RSW 37 1464380000(1)2009-11...
  • Page 58 ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM COMPONENT LAYOUT (continues) 14-15-16-17-18-19 S300840 RSW 37 1464380000(1)2009-11...

  • Page 59: Wiring Diagram

    Manual vacuum system motor (optional) Horn switch Drive speed potentiometer Hood safety switch Emergency push-button Main broom, vacuum fan and filter shaker switch Driver’s seat safety microswitch Side broom microswitch Drive system switch Manual vacuum system switch (optional) Working light switch RSW 37 1464380000(1)2009-11...
  • Page 60 ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM WIRING DIAGRAM (continues) S300843 RSW 37 1464380000(1)2009-11...
  • Page 62 14600 21st Avenue North Plymouth, MN 55447-3408 www.clarkeus.com Phone: 800-253-0367 Fax: 800-825-2753 ©2010 Nilfisk-Advance, Inc. A Nilfisk-Advance Brand...

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