WACKER Group 0007587, Repair Manual

Page 1: ...www wackergroup com Walk Behind Trowels CT 30 CT 36 CT 48 REPAIR MANUAL 0112103 001 0600 en 0 1 1 2 1 0 3 ...

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Page 3: ...des information and procedures to safely repair and maintain this WACKER model For your own safety and protection from injury carefully read understand and observe the safety instructions described in this manual THE INFORMATION CONTAINED IN THIS MANUAL WAS BASED ON MACHINES IN PRODUCTION AT THE TIME OF PUBLICATION WACKER CORPORATION RESERVES THE RIGHT TO CHANGE ANY PORTION OF THIS INFORMATION WIT...

Page 4: ...1 101 101 101 00010101 00010101 00010101 00010101 00010101 Pro Shift Nameplate A nameplate listing the Model Number and Serial Number OR the Model Number Item Number Revision and Serial Number is attached to each unit Please record the information found on this plate so it will be available should the nameplate become lost or damaged When ordering parts or requesting service information you will a...

Page 5: ... Twist Pitch Control Exploded View 2 2 2 4 Twist Pitch Control Cable Replacement 2 4 2 5 Upper Handle Pro Shift Exploded View 2 6 2 6 Pro Shift Pitch Control Cable Replacement 2 8 3 Clutch 3 1 BeltReplacement 3 1 3 2 Belt Drive Exploded View 3 2 3 3 ClutchReplacement 3 3 3 4 Clutch Exploded View 3 4 3 5 ClutchOverhaul 3 5 4 Spider 4 1 Trowel Assembly Exploded View 4 1 4 2 Spider 4 2 5 Drivetrain 5...

Page 6: ...which could damage machine or components WARNING Warns of conditions or practices which could lead to personal injury or death 1 2 Laws Pertaining to Spark Arresters Notice Some states require that in certain locations spark arresters be used on internal combustion engines A spark arrester is a device designed to prevent the discharge of sparks or flames from the engine exhaust It is often require...

Page 7: ...ks and hazards associated with it NEVER touch engine or muffler while the engine is onorimmediatelyafterithasbeenturnedoff These areas get hot and may cause burns NEVERuseaccessoriesorattachmentswhichare notrecommendedbyWACKER Damagetoequip ment and injury to the user may result NEVER operate machine with the belt guard miss ing Exposed drive belt and pulleys create poten tially dangerous hazards ...

Page 8: ...engine is flooded or the smell of gasoline is present A stray spark could ignite fumes DO NOT use gasoline or other types of fuels or flammable solvents to clean parts especially in enclosed areas Fumes from fuels and solvents can become explosive ALWAYS keep area around muffler free of debris such as leaves paper cartons etc A hot muffler could ignite them starting a fire ALWAYS replace worn or d...

Page 9: ... CT 30AGT CT36ADP CT 36AGT CT 48ADP CT 48AGT 30 762 30 762 36 914 36 914 48 1220 48 1220 60 100 125 165 60 100 125 165 60 100 125 165 Trowel 4 Mobil SHC634 Approx 45 1330 0 15 TrowelDiameter in mm Number of Blades GearboxLubrication type oz ml SpeedRange rpm Pitch Range degrees ...

Page 10: ...rowel blade lift The trowels can be tilted from 0 15 The speed of the trowels ranges from 60 165 rpm depending on the model 1 9 PeriodicMaintenanceSchedule The chart below lists basic trowel maintenance Refer to engine manufacturer s Operator s Manual for information on engine maintenance A copy of the engine Operator s Manual was supplied with the machine when it was shipped Daily After After Eve...

Page 11: ...ect throttle cable e to throttle lever f 5 Install cable clamp h to take up excess throttle cable 6 Adjustthrottlecablesothatengineisinidlewhenthrottle control lever is in the idle position Tighten cable 7 Reinstall air filter wing nut filter cover and second wing nut d 1001RM01 d e f 1001RM02 h g 1001RM17 a b c j Thethrottlecontrolisusedtovarythespeedoftheengine and to control the rpm of the trow...

Page 12: ... 2 2 GUIDE HANDLE TROWEL REPAIR 1013SD79 2 3 Upper Handle Twist Pitch Control Exploded View 1 1 2 3 4 5 6 7 9 10 11 8 12 16 15 14 13 23 4 3 18 22 19 20 21 24 25 21 28 27 26 33 29 30 31 32 17 N2 34 N2 N1 ...

Page 13: ...15 Screw M5x25 1 16 Screw 8 32x1 4 2 17 Knob 1 Ref Description Qty N2 Lubricate threads before assembly N1 Fill bearing with grease before assembly Ref Description Qty 18 Screw 3 8 16x1 3 8 1 19 Casing cable 1 20 Cable throttle 1 21 Wiring harness 1 22 Cable control blade 1 23 Rod handle adjustment 1 24 Cap screw head 1 25 Nut lock M5 1 26 Grommet 2 27 Washer B5 3 1 28 Screw M5x45 1 29 Nut BM5 1 3...

Page 14: ...rol cable d 2 Disengage cable from fork e and slide through pulley c 3 Remove two M8 screws a holding handle to handle base b Carefullypullhandleandcontrolcableaway from handle base 4 Remove M6 screw g from handle Remove M6 screw m from underside of handle 5 PullTwistControlassembly j andpitchcontrolcable k from handle 6 Drive roll pin h from Twist Control assembly Remove cable ...

Page 15: ...ssembly into handle lining up holesinhandle AttachM6screw m totheunderneath of handle 4 Apply Loctite 243 or equivalent to threads of M6 screw g Attach to top of handle Torque to 6 ft lbs 8 Nm 5 Threadcablethroughhandlebase b andoverpulley c Slide handle into base 6 Apply Loctite 243 or equivalent and attach two M8 screws a to handle Torque to 16 ft lbs 22 Nm 7 Threadcontrolcablefork e andattachre...

Page 16: ...LE TROWEL REPAIR 2 5 Upper Handle Pro Shift Exploded View 1023SD74 1 2 3 4 5 4 6 7 10 10 8 8 10 11 13 12 9 11 10 17 16 14 18 23 24 25 26 27 28 29 30 21 6 31 20 22 33 34 26 35 36 37 38 39 40 41 32 19 9 14 15 16 26 20 21 ...

Page 17: ...ck M12 2 17 Housing Pro Shift 1 18 Handle adjustable 1 19 Lever throttle control 1 20 Clamp 2 21 Screw M5x25 2 Ref Description Qty Ref Description Qty 22 Knob 1 23 Screw 3 8 16x1 3 8 1 24 Casing cable 1 25 Cable throttle 1 26 Wiring harness w lever 1 27 Cable pitch control 1 28 Screw 8 32x1 4 2 29 Rod handle adjustment 1 30 Knob pitch control 1 31 Pin roll 1 32 Grommet 2 33 Washer 1 34 Screw 1 35 ...

Page 18: ...able from fork r and slide through pulley p 4 Pull the Pro Shift handle all the way back 5 Remove two M8 screws n holding handle to handle base o Carefullypullhandleandcablecontrolaway from handle base 6 Remove M6 screw k from handle Pull Pro Shift assembly and pitch control cable from handle 7 Remove threaded rod h from housing j Note On some models the threaded rod may be replaced by a bolt 8 Re...

Page 19: ...rough handle legs x If so equipped install retaining washer 3 Using pliers squeeze handle legs x together and slip handle into place on the pivot tubes Make sure that the handle is seated properly 4 Using C clamps evenly compress the wave springs against the housing until the holes in the handle are flush with the pivot tubes w 5 Slide torsional spring z over mandrel y and insert assembly between ...

Page 20: ...octite 243 or equivalent to M6 screw c and reinstall in handle Torque to 6 ft lbs 8 Nm 11 Push Pro Shift handle fully forward Thread cable through handle base d and over pulley f Slide handle into base 12 Apply Loctite 243 or equivalent and attach two M8 screws e to handle Torque to 16 ft lbs 22 Nm 13 Install hitch pin into handle 14 Thread control cable g through fork h Adjust retaining nuts j un...

Page 21: ...t slipping To replace belt 1 Disconnect spark plug lead WARNING To avoid accidental starting of the engine always disconnect spark plug lead before working on ma chine k m n o 1019SD18 2 Loosen the two M8x16 screws m and remove belt guard k 3 Slowly turn pulley n and roll belt o off Note The clutch and the pulley are aligned at the factory and neither should be removed during belt replacement 4 In...

Page 22: ...0 11 13 12 8 9 1 Mount beltguard 1 2 Clutch centrifugal 1 3 Washer 5 16x1 1 8x11 Ga 1 4 Screw 5 16x18x1 1 4 1 5 Beltguard 1 6 Washer B8 4 2 7 Screw M8x20 2 8 Pulley single groove 1 9 V belt 1 10 Screw M8x30 2 11 Washer 5 16 1 12 Plate belt guard 1 13 Screw M8x25 1 Ref Description Qty ...

Page 23: ...in screw d 4 6 turns to protect threads in crankshaft Push against bolt head rather than directly against shaft end 4 Remove key a Inspect key and keyways for signs of shearing Replace key if deformed or if edges are rounded Installation 1 Coat engine crankshaft with Alvania 2 or equivalent Install key a in keyway 2 Slideclutchassembly b overcrankshaft Makesure that keyway lines up with key Tap wi...

Page 24: ...IR 3 4 Clutch Exploded View 1 2 3 1017SD07 7 6 8 5 4 Ref Description Qty 1 Clutch centrifugal incl 2 8 1 2 Setscrew M8x12 2 3 Plate clutch 1 4 Spring clutch 1 5 Shoe clutch 4 6 Bearing ball 1 7 Clutch drum 1 8 Pulley clutch 1 ...

Page 25: ...if necessary 3 Inspect bearing 6 for free motion on shaft Replace if necessary Installation CAUTION Do not grease or oil pulley shaft or clutch drum 1 Slide clutch drum 7 over clutch pulley shaft 8 2 Slide clutch spring 4 over clutch shoe 5 Slide clutch shoe over clutch pulley shaft 3 Slide clutch plate 3 over clutch pulley shaft Tighten setscrew 2 Clutch shoe should move freely over shaft and clu...

Page 26: ...3 6 3 CLUTCH TROWEL REPAIR Notes ...

Page 27: ... Shaft 1 6 Retainingring ext 2 7 Ring blade lift incl 8 1 8 Bearing sleeve 1 9 Screw armretainer 4 10 Fitting grease 4 11 Hub spider assy 1 12 Washer 1 Ref Description Qty Ref Description Qty 13 Screw M8x20 1 14 Cap plug 1 Set comboblades 1 Set finishblades 1 Set floatblades 1 16 Cap plug 4 17 Shaft trowelarm 4 18 Screw5 16 18x1 1 2 8 19 Nut3 8 16 4 20 Pivot trowelblade 4 21 Screw3 8 16x1 3 8 8 22...

Page 28: ...emove spark plug to avoid acci dentally starting engine when turning trowel blades Trowel arms are free to rotate Be careful when handling trowel to avoid pinching hand or fingers betweentrowelblades 4 Carefully hold trowel arms Remove M8 screw m and washer k holding spider to gearcase output shaft 5 Pull blade assembly from gearcase output shaft 6 On CT48 models only remove four M8 bolts holding ...

Page 29: ...wel arm Using thickness gauge tighten bolts until 1 16 remains between retaining ring and trowel arm 5 Check for free movement of lifting ring over spider Trowel blades should pivot freely Slide blade assembly over gearcase output shaft 6 Apply Loctite 243 or equivalent to screw Install screw m andwasher k throughspidertogearcase output shaft Carefully hold the trowel arms and torque to 16 ft lbs ...

Page 30: ...4 4 4 SPIDER TROWEL REPAIR Notes ...

Page 31: ...onnector wire 1 5 Screw 8 32x1 4 1 6 Key 3 16x1 13 16 2 7 Screw M8x25 3 8 Wire assembly 1 9 Washer B8 4 15 10 Gearbox assembly 1 Ref Description Qty 11 Ring trowel guard 1 12 Nut wing 1 13 Cover filter 1 14 Nut wing 1 15 Filter air 5 16x18x1 1 4 1 20 Screw M8x30 2 22 Plate belt guard 1 23 Screw M8x45 4 24 Screw M8x20 2 25 Nut lock M8 4 Ref Description Qty 1001RM10 ...

Page 32: ...trowelguard 7 For engine overhaul procedures refer to engine manufacturer srepairmanual Installation 1 Line up engine with mounting holes Reinstall four M8 locknuts d eight B8 washers e and four M8x45 screws f Tighten to 55 in lbs 6 2 Nm 2 Reinstall clutch assembly as described in Section 3 3 Clutch Replacement Removal 3 Reinstall belt as described in Section 3 1 Belt Replacement 4 Reconnect elect...

Page 33: ...onnector wire 1 5 Screw 8 32x1 4 1 6 Key 3 16x1 13 16 2 7 Screw M8x25 3 8 Wire assembly 1 9 Washer B8 4 15 10 Gearbox assembly 1 Ref Description Qty 1001RM10 Ref Description Qty 11 Ring trowel guard 1 12 Nut wing 1 13 Cover filter 1 14 Nut wing 1 15 Filter air 5 16x18x1 1 4 1 20 Screw M8x30 2 22 Plate belt guard 1 23 Screw M8x45 4 24 Screw M8x20 2 25 Nut lock M8 4 ...

Page 34: ...r g and belt guard plate h 6 Remove retaining ring from fork ring shaft Slide shaft out from lifting fork and gearcase Refer to Section 4 1 Trowel Assembly Exploded View 7 Slide fork free of lifting ring Disconnect pitch control cable 8 Remove two M8 screws holding handle to handle base Carefully pull handle and control cable away from handle base 9 Remove two M8 screws n from front of gearcase 10...

Page 35: ...6 2 Nm Torque rear screws to 16 ft lbs 22 Nm 5 If necessary reinstall pitch control cable to fork Install fork around lifting ring 6 Slide shaft through fork and gearcase Install retaining ring 7 Replace belt guard plate h 5 16 washer g and M8 screw f Torque screws to 16 ft lbs 22 Nm 8 Replace belt guard mount b two M8 screws d and two B8 washers e Torque screws to 16 ft lbs 22 Nm 9 Replace key a ...

Page 36: ...6 1 15 Bearing 1 16 Cover gearbox side 1 17 Seal shaft 1 Shim 005 blue AR Shim 003 green AR Shim 001 amber AR Shim 010 brown AR 31 18 30 31 1 3 2 4 5 6 7 10 16 9 12 13 14 15 5 10 20 19 25 26 27 18 8 23 5 29 11 11 17 19 24 28 22 21 19 Bearing tapered 2 20 Retaining ring ext 1 21 O ring 1 22 Cover gear 1 23 Shaft gear drive 1 24 Seal shaft 1 25 Key 1 26 Screw M8x25 4 27 Key 1 28 Retaining ring int 1...

Page 37: ...tighten to 16 ft lbs 22Nm CAUTION Rotateshaftbyhandwhiletighteningcover If shaft begins to bind before cover is tight DO NOT continue tightening or bearings may be damaged Remove cover and install additional shims before proceeding DO NOT overshim or shaft play will become excessive resulting in an early failure CAUTION Checksideplaybyplacinganindicatornear the end of the shaft Side play should no...

Page 38: ...5 8 5 DRIVETRAIN TROWEL REPAIR Notes ...

Page 39: ...rty or worn Clean or replace plug 4 Fuel air mixture needs adjustment Adjust 5 Dirty air filter Clean or replace filter 6 Dirty fuel filter Replace filter 7 Engine bolts or parts loose or missing Inspect and tighten all bolts 8 Engine RPM set wrong Adjust RPM 9 Belt rubbing pulleys out of alignment Align pulleys 1 Belt broken Replace belt 2 Clutch not engaging Inspect clutch for damage 3 Gearcase ...

Page 40: ...6 2 6 TROWEL REPAIR TROUBLESHOOTING Notes ...

Page 41: ...reads 28824 5 ml Hernon 431 and for sealing weld porosity wicking 25316 10 ml Omnifit 1710 230LL Gaps up to 0 005 0 13 mm Temp range 65 to 300 degrees F 54 to 149 degrees C Loctite 609 Green Medium strength retaining compound for slip or press fit 29314 5 ml Hernon 822 of shafts bearings gears pulleys etc Omnifit 1730 230L Gaps up to 0 005 0 13 mm Temp range 65 to 300 degrees F 54 to 149 degrees C...

Page 42: ... 271 282 383 353 479 1 1 8 5 8 1 Ft Lb 1 357 Nm 1 Inch 25 4 mm In Lb Metric Fasteners DIN Inch Fasteners SAE Size Ft Lb Nm Ft Lb Nm Ft Lbs Nm Inch Metric Inch Metric M3 11 1 2 14 1 6 19 2 1 7 32 5 5 2 5 M4 26 2 9 36 4 1 43 4 9 9 32 7 3 M5 53 6 0 6 8 5 7 10 5 16 8 4 M6 7 10 10 14 13 17 10 5 M8 18 25 26 35 30 41 1 2 13 6 M10 36 49 51 69 61 83 11 16 17 8 M12 63 86 88 120 107 145 3 4 19 10 M14 99 135 ...

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