Wacker Neuson CT 36, Repair Manual

Page 1: ...www wackergroup com Walk Behind Trowels CT 36 CT 48 REPAIR MANUAL 0163091en 003 1007 0 1 6 3 0 9 1 E N...

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Page 3: ...happening in the future This manual provides information and procedures to safely repair and maintain the above Wacker model s For your own safety and protection from injury carefully read understand...

Page 4: ...ment please contact Wacker Corporation 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 porti...

Page 5: ...2 1 Dimensions and Weight 18 2 2 Engine 20 2 3 Trowel 24 2 4 Sound and Vibration Data 25 3 Operation 26 3 1 Application 26 3 2 New Machine Set up 26 3 3 Recommended Fuel 26 3 4 Installing Blades 27 3...

Page 6: ...onal Weights 51 4 15 Lifting 52 4 16 Storage 54 4 17 Troubleshooting 55 5 Guide Handle 56 5 1 Replacing the Throttle Cable 56 5 2 Adjusting the Throttle Lever 58 5 3 Upper Handle Twist Pitch Control E...

Page 7: ...ing the Spider 88 7 8 Rebuilding the Lift Ring Assembly 90 8 Drivetrain 92 8 1 Drivetrain Exploded View 92 8 2 Drivetrain Components 93 8 3 Engine Removal 94 8 4 Engine Installation 96 8 5 Engine Wiri...

Page 8: ...us situation which if not avoided could result in minor or moderate injury NOTICE Used without the safety alert symbol NOTICE indicates a hazardous situation which if not avoided could result in prope...

Page 9: ...ve machine running unattended 1 2 5 NEVER operate the machine with the beltguard missing Exposed drive belt and pulleys create potentially dangerous hazards that can cause serious injuries 1 2 6 NEVER...

Page 10: ...nd follow the warning instructions in the engine owner s manual and the safety guidelines below Failure to follow the warnings and safety guidelines could result in severe injury or death 1 3 1 DO NOT...

Page 11: ...f fuels or flammable solvents to clean parts especially in enclosed areas Fumes from fuels and solvents can become explosive 1 4 5 DO NOT remove blades while the machine is hanging overhead 1 4 6 ALWA...

Page 12: ...Safety Information CT 36 CT 48 wc_si000139gb fm 12 1 5 Label Locations...

Page 13: ...ER Engines emit carbon monoxide operate only in well ventilated area Read the Operator s Manual No sparks flames or burning objects near the machine Shut off the engine before refueling WARNING Hot su...

Page 14: ...n i s h i t G l e i t s c h e i b e v o m B e t o n g l t t e r e n t f e r n e n b e v o r d a s G e r t u b e r K o p f h h e g e h o b e n w i r d G l e i t s c h e i b e k a n n f a l l e n u n d...

Page 15: ...infor mation found on this plate so it will be available should the nameplate become lost or dam aged When ordering parts or requesting ser vice information you will always be asked to specify the mo...

Page 16: ...formation CT 36 CT 48 wc_si000139gb fm 16 Label Meaning Open the fuel flow valve Close the choke Turn engine key switch to ON position Place throttle in the IDLE position Pull the rewind starter Open...

Page 17: ...CT 36 CT 48 Safety Information wc_si000139gb fm 17 Press the stop button Turn engine key switch to OFF position Close the fuel flow valve Label Meaning...

Page 18: ...e A Variable Speed V Engine Horse Power 4 5 6 8 9 11 13 Handle Type Item No L mm in Pitch Type Weight kg lbs Solid 0159659 1740 68 5 Twist 10 21 Folding 0159660 1740 68 5 Twist 12 26 5 Adjustable Fold...

Page 19: ...x36x41 94 208 103 226 CT 36 8A V 0009442 915x915x686 36x36x27 2005x915x1040 79x36x41 94 208 103 226 CT 36 9 0009444 915x915x686 36x36x27 2005x915x1040 79x36x41 90 199 98 217 CT 36 9 V 0009447 915x915x...

Page 20: ...031 0 6 0 7 0 024 0 028 Engine Speed full load rpm 3800 100 Engine Speed idle rpm 1450 100 1400 100 Clutch engagement rpm 1800 Valve Clearance cold intake exhaust mm in 0 15 0 006 0 20 0 008 0 07 0 1...

Page 21: ...0 7 0 8 0 028 0 031 Engine Speed full load rpm 3800 100 Engine Speed idle rpm 1450 100 1400 100 Clutch engagement rpm 1800 Valve Clearance cold intake exhaust mm in 0 15 0 006 0 20 0 008 0 07 0 13 0...

Page 22: ...031 Engine Speed full load rpm 3800 100 Engine Speed idle rpm 1450 100 1400 100 Clutch engagement rpm 1800 Valve Clearance cold intake exhaust mm in 0 15 0 006 0 20 0 008 0 07 0 13 0 0028 0 0051 0 17...

Page 23: ...Electrode Gap mm in 0 7 0 8 0 028 0 031 Engine Speed full load rpm 3800 100 Engine Speed idle rpm 1450 100 Clutch engagement rpm 1800 Valve Clearance cold intake exhaust mm in 0 15 0 006 0 20 0 008 A...

Page 24: ...eter mm in Number of Blades Gear Box Lubrication type ml oz Speed Range rpm Pitch Range degrees Trowel CT 36 5A 0009438 0620106 915 36 4 Mobil Glygoyle 460 Approx 620 21 60 125 0 30 CT 36 6 0009443 CT...

Page 25: ...d pressure level LpA at the operator s location The weighted effective acceleration value determined according to ISO 8662 Part 1 is C m s2 The sound and vibration specifications were obtained with th...

Page 26: ...depend on operator skill and job conditions DO NOT use this machine for any application other than troweling concrete 3 2 New Machine Set up Trowels are shipped from the factory with the handle remove...

Page 27: ...r pans and finish blades Note Trowel blades must NOT be interchanged i e do NOT put larger diameter blades on a smaller diameter trowel 3 4 1 Finish blades are flat on both edges and can be installed...

Page 28: ...the way forward away from the operator OR turn the twist pitch control handle counterclockwise as far as possible Connect the cable to the fork k as shown and adjust the cable nut m so the cable is sn...

Page 29: ...CT 36 CT 48 Operation wc_tx000373gb fm 29 wc_gr001758 e f g h j k...

Page 30: ...fm 30 3 6 Controls See Graphic wc_gr003219 Ref Description Ref Description a Throttle lever d Handle height adjustment if equipped b Stop button e Foldable handle adjustment if equipped c Twist pitch...

Page 31: ...r loses his her grip on the trowel the engine control module will sense that the machine is spinning and shut off the engine The momentum of the spinning trowel will engage the brake and stop the hand...

Page 32: ...is started when the throttle is not in the idle position the engine should not start This is a feature of the engine control module that prevents wide open throttle startup 3 9 4 Pull starter rope j D...

Page 33: ...raphic wc_gr003219 wc_gr001098 3 10 1 Reduce engine RPM to idle by moving the throttle lever to idle position a1 3 10 2 Push the stop button b 3 10 3 Turn engine switch to OFF h2 3 10 4 Close fuel val...

Page 34: ...tarted when the throttle is not in the idle position the engine should not start This is a feature of the engine control module that prevents wide open throttle startup 3 11 4 Pull starter rope j Do n...

Page 35: ...op Wacker See Graphic wc_gr003219 wc_gr002747 3 12 1 Reduce engine RPM to idle by moving the throttle lever to idle position a1 3 12 2 Push the stop button b 3 12 3 Turn engine switch to OFF h1 3 12 4...

Page 36: ...or not functioning properly 3 14 Operation See Graphic wc_gr003239 ALWAYS test the function of the engine control module before operating the trowel DO NOT operate the trowel if the engine control mo...

Page 37: ...ch set of work passes be at 90 to the previous set of work passes This will help prevent the creation of valleys in the slab surface For example in the illustration the second set of work passes 2 is...

Page 38: ...sed when the input shaft is rotated and is shifted out from its seated position This is accomplished when the gear on this shaft rotates working against the output shaft gear forcing the shaft out If...

Page 39: ...operator to decrease pitch For final finishing stages it is sometimes desirable to add weights to the trowel guard rings to increase the burnishing force Wacker supplies weight kits for this purpose R...

Page 40: ...n on engine maintenance Daily After first 20 hrs Every 50 hrs Every 100 hrs Every 300 hrs Check fuel level Check engine oil level Inspect fuel lines Inspect air filter Replace as needed Check external...

Page 41: ...l devices and systems may be performed by any repair establishment or individual Daily After first 20 hours Every 2 weeks or 50 hrs Every month or 100 hrs Every year or 300 hrs Every 500 hrs Check fue...

Page 42: ...e interests of environmental protection place a plastic sheet and a container under the machine to collect any liquid which drains off Dispose of this liquid in accordance with environmental protectio...

Page 43: ...id which drains off Dispose of this liquid in accordance with environmental protection legislation 4 4 2 Remove the oil drain cap a 4 4 3 Allow the oil to drain 4 4 4 Install the drain cap 4 4 5 Fill...

Page 44: ...low flash point solvents for cleaning the air cleaner A fire or explosion could result To service 4 5 1 Remove air cleaner cover a Remove both elements and inspect them for holes or tears Replace dama...

Page 45: ...ry and dusty conditions the elements should be maintained daily Replace an element when saturated with dirt that cannot be removed 4 6 1 Remove the air cleaner cover a Remove the filter assembly by pu...

Page 46: ...ing the engine Do not touch the muffler while it is hot Note Refer to the Technical Data for the recommended spark plug type and the electrode gap setting 4 7 1 Remove the spark plug and inspect it 4...

Page 47: ...le solvent Dry and reinstall them 4 8 4 Turn the fuel valve on and check for leaks 4 9 Cleaning Fuel Strainer Wacker See Graphic wc_gr001093 4 9 1 To remove water and dirt close the fuel lever and rem...

Page 48: ...he blades will engage unless the belt is removed from the machine Adjust engine to the no load or idle speed per the Technical Data 4 10 1 Start the engine and allow it to warm up to normal operating...

Page 49: ...ill engage unless the belt is removed from the machine The pilot screw a is fitted with a limiter cap to prevent excessive enrichment of the air fuel mixture in order to comply with emission regulatio...

Page 50: ...ng To replace the drive belt 4 12 1 Disconnect the spark plug lead To avoid accidental starting of the engine always disconnect the spark plug lead before working on machine 4 12 2 Loosen the screws d...

Page 51: ...ck quantity through plug a located on side of gearbox Oil level should be to bottom of the plug threads See Technical Data for oil quantity and type 4 14 Optional Weights To install optional weights p...

Page 52: ...et The lumber must be long enough to extend past the ring guard c Balance the weight between the partners and lift the machine by the handle and the lumber To reduce risk of back injury while lifting...

Page 53: ...CT 36 CT 48 Maintenance wc_tx000374gb fm 53...

Page 54: ...ove spark plug and pour 15 ml ounce of SAE 30 engine oil into the cylinder Replace spark plug and crank engine to distribute oil Refer to engine manual Clean dirt from cylinder cylinder head fins blow...

Page 55: ...throttle lever and cable for proper operation Engine runs poor trowel operation Check drive belt for wear or damage Check clutch for wear or damage Clean debris from moving parts and trowel arms Engin...

Page 56: ...and the casing fastener from the throttle control lever b and remove the throttle cable from the machine Assembly 5 1 6 Place the engine s throttle control lever in the idle position Connect the thro...

Page 57: ...CT Repair Guide Handle wc_tx000551gb fm 57 wc_gr003362 Honda Honda Wacker d a c b f e g f e g f e g...

Page 58: ...so that the engine s throttle control can reach the idle slow position 5 2 2 Remove the screw a on top of throttle lever b and lift off the throttle lever 5 2 3 Position the throttle lever in the idl...

Page 59: ...CT Repair Guide Handle wc_tx000551gb fm 59 wc_gr003361 1 2 a e d c b...

Page 60: ...Guide Handle CT Repair wc_tx000551gb fm 60 5 3 Upper Handle Twist Pitch Control Exploded View...

Page 61: ...n 1 Handle 13 Pin 3 Push button switch 14 Retaining ring 4 Nut 15 Spring 5 Bearing holder 16 Ball 6 Wiring harness 17 Tie cable 7 Cable 18 Hex head screw 8 Throttle cable 19 Hex head screw 9 Kit CT th...

Page 62: ...hread the pitch control cable through the upper handle Attach the pitch control device i twist pitch or Pro Shift to the upper handle On models with twist pitch control turn the knob counterclockwise...

Page 63: ...CT Repair Guide Handle wc_tx000551gb fm 63 wc_gr003360 a d f b h g c d e...

Page 64: ...ttach the knob f to the twist control assembly c 5 6 6 Place the pitch control cable d into the twist control assembly and secure it with the roll pin e 5 6 7 Lubricate the threads g on the twist cont...

Page 65: ...CT Repair Guide Handle wc_tx000551gb fm 65 wc_gr003363 g a d e b f c...

Page 66: ...s 60 5 7 3 Pull the lower handle 17 from the gearbox 5 7 4 If replacing the pulley 25 pull the cotter pin 46 from the clevis pin 42 and remove the pulley Assembly 5 7 5 If removed replace the pulley 2...

Page 67: ...the stop screw a carry out the following procedures Removal 5 8 1 Remove the protective boot b 5 8 2 Disconnect the wire c 5 8 3 Unthread the stop switch from the handle Installation 5 8 4 Thread the...

Page 68: ...Guide Handle CT Repair wc_tx000551gb fm 68 Notes...

Page 69: ...nge the belt is the same for both clutches To replace the drive belt 6 1 1 Disconnect the spark plug lead To avoid accidental starting of the engine disconnect the spark plug lead before working on th...

Page 70: ...Clutch Ref Description Ref Description 3 Beltguard 53 Hex head screw 4 Beltguard plate 54 Hex head screw 23 Clutch assembly 69 Fender washer 24 Pulley 70 Flat steel washer 26 V belt 72 Washer 36 Space...

Page 71: ...tion Ref Description 3 Upper belt guard 58 Hex head screw 4 Beltguard plate 69 Fender washer 23 Clutch 70 Washer 24 Clutch pulley 71 Washer 26 Belt 84 Key 36 Spacer 127 Lower beltguard 51 Screw 132 Ke...

Page 72: ...crankshaft Push against the bolt head rather than directly against the threads of the crankshaft 6 4 4 Remove the spacer 36 and the key 84 from the crankshaft Inspect the key and the keyways for sign...

Page 73: ...52gb fm 73 6 5 Standard Clutch Exploded View Ref Description Ref Description 1 Clutch assembly incl 2 8 5 Clutch shoe 2 Setscrew 6 Ball bearing 3 Clutch plate 7 Clutch drum 4 Spring 8 Clutch pulley wc...

Page 74: ...e torch Then while protecting your hands from any hot surface pick up the clutch pulley bearing assembly a and strike it against a wooden or similar surface b The force of the blow should free the bea...

Page 75: ...CT Repair Clutch wc_tx000552gb fm 75 wc_gr003364 a b wc_gr002068 2 3 4 5 7 6 8 1...

Page 76: ...move the bolt 58 that secures the clutch pulley 24 to the gearbox input shaft and remove the clutch pulley 6 7 5 Remove the key 132 Installation 6 7 6 Install the key 132 onto the gearbox input shaft...

Page 77: ...CT Repair Clutch wc_tx000552gb fm 77 81 4 50 23 84 74 51 3 36 71 24 132 26 70 58 69 53 127 wc_gr003383...

Page 78: ...Spider CT Repair wc_tx000553gb fm 78 7 Spider 7 1 Spider Assembly Exploded View...

Page 79: ...ad screw 10 Bearing holder 57 Hex head screw 11 Tube 59 Lifting bolt 12 Yoke 61 Setscrew 13 Link 62 Screw 14 Eccentric adjuster 64 Screw 27 Bearing sleeve 65 Plug threaded 28 Ball bearing 67 Fender wa...

Page 80: ...ly starting the engine when turning the trowel blades 7 3 1 Pitch the blades so that they lie flat 7 3 2 Remove the screws a that secure the blade b to the blade arm and remove the blade Do so for all...

Page 81: ...CT Repair Spider wc_tx000553gb fm 81 wc_gr003365 a b...

Page 82: ...ding outside of the spider 7 4 5 Inspect the arm for straightness Use the flattest and smoothest surface available and two spacers h of equal size Place the spacers on the surface Set the arm on the s...

Page 83: ...CT Repair Spider wc_tx000553gb fm 83 wc_gr003356 a b c e d x x x x x x 180 g f i h...

Page 84: ...above the blade labeled 1 7 5 6 Measure the distance x from the handle at the stop switch b to the floor 7 5 7 Rotate the entire trowel 90 counterclockwise The brake will engage and the blades will s...

Page 85: ...CT Repair Spider wc_tx000553gb fm 85 wc_gr003357 x a c d b 1 2 3 4...

Page 86: ...5 to release the yoke 12 from the gearbox Slide the yoke free of the guard ring 7 6 4 Lift the trowel by the lifting eye to gain access to the underside of the spider The trowel arms are free to rotat...

Page 87: ...CT Repair Spider wc_tx000553gb fm 87...

Page 88: ...the blade lift ring over the spider 7 7 5 Apply Loctite 243 or equivalent to the screw 55 use the screw and the washer 72 to secure the spider to the output shaft Torque the screw to 25 Nm 18 ft lbs 7...

Page 89: ...CT Repair Spider wc_tx000553gb fm 89...

Page 90: ...ompound that secures it to the bearing holder 9 Assembly 7 8 6 Lubricate the bearing sleeve 27 with a thin film of grease and press it into the blade lift ring 9 7 8 7 Lubricate the ball bearing 28 wi...

Page 91: ...CT Repair Spider wc_tx000553gb fm 91 wc_gr003358 88 28 28 10 10 11 59 9 9 27 27...

Page 92: ...Drivetrain CT Repair wc_tx000554gb fm 92 8 Drivetrain 8 1 Drivetrain Exploded View a...

Page 93: ...s Ref Description Ref Description 1 Guard ring 68 Lockwasher 4 Beltguard plate 73 Flat washer 36 Spacer 76 Flat washer 37 Engine control module gyro switch 78 Locknut 49 Stud 79 Locknut 50 Screw 98 Oi...

Page 94: ...ol module gyro switch See section Engine Wiring 8 3 3 Remove the drive belt as described in section Replacing the Drive Belt 8 3 4 Remove the clutch assembly as described in section Replacing the Stan...

Page 95: ...CT Repair Drivetrain wc_tx000554gb fm 95 a...

Page 96: ...drive shaft and slide on the spacer 36 8 4 5 Reinstall the clutch assembly as described in section Replacing the Clutch 8 4 6 Reinstall the drive belt as described in section Replacing the Drive Belt...

Page 97: ...CT Repair Drivetrain wc_tx000554gb fm 97 a...

Page 98: ...wc_tx000554gb fm 98 8 5 Engine Wiring 3 4 5 11 10 10 10 10 12 12 13 7 6 B B B G G G G B Y Y Y 3 4 5 7 6 B B B B B Y Y Or Or 3 4 5 7 6 B B B B Y Y Y 3 4 5 7 6 B B B B B Y Y Or Or wc_gr003370 2 2 2 2 6...

Page 99: ...der machines the handle serves as the connection to ground Ref Description Ref Description 1 Spark plug 8 Handle 2 Ignition module 9 Handle ground wire 3 Engine ON OFF switch 10 Engine ground wire 4 E...

Page 100: ...Drivetrain CT Repair wc_tx000554gb fm 100 8 7 Wiring Diagrams B W Or Or Y B B B B B B Y Y Y G G B B B Y B B B Wacker 1 1 2 2 3 3 4 4 5 5 14 6 7 14 8 Honda 7 9 10 8 wc_gr003369 G G 9 10 6...

Page 101: ...lder machines the handle serves as the connection to ground Ref Description Ref Description 1 Spark plug 8 Handle 2 Ignition module 9 Handle ground wire 3 Engine ON OFF switch 10 Engine ground wire 4...

Page 102: ...50 that secure the beltguard plate 4 to the engine and remove the beltguard plate 8 9 7 Remove the engine as described in section Engine Removal 8 9 8 Remove the screws 56 that secure the gearbox to t...

Page 103: ...CT Repair Drivetrain wc_tx000554gb fm 103 wc_gr003359...

Page 104: ...Drivetrain CT Repair wc_tx000554gb fm 104 8 10 Gearbox Exploded View wc_gr003367 93 94 1...

Page 105: ...arbox 38 Relief valve 6 Gearbox cover 39 Plug threaded 7 Gearbox cover 54 Hex head screw 18 Worm gear 82 Key 19 Input shaft 83 Key 20 Output shaft 86 Key square 21 Brake cone 87 Retaining ring 22 Brak...

Page 106: ...e with environmental protection legislation 8 12 3 Remove the screws 54 from the top cover 6 and remove the top cover Inspect the O ring 89 and the shims 91 92 replace them if worn or damaged Using a...

Page 107: ...CT Repair Drivetrain wc_tx000554gb fm 107 20 e f 29a 29b 18 6 89 d c 29a 33 87 wc_gr003157...

Page 108: ...sing a hydraulic press 8 12 12 Remove the seal 32 from the cover 8 12 13 Remove the spring 34 from the gearbox 8 12 14 Remove the input shaft assembly g from the gearbox and remove the spacer 35 from...

Page 109: ...CT Repair Drivetrain wc_tx000554gb fm 109 b a 19 29 35 32 wc_gr003366 93 94 22 94 29 30 30 g h...

Page 110: ...worm gear 8 13 10 Press the roller bearing race into the top cover Also add O ring 89 and shims 91 92 to the top cover If the shims are damaged or worn replace them with the equivalent type and number...

Page 111: ...CT Repair Drivetrain wc_tx000554gb fm 111 wc_gr003367 93 94 1 wc_gr003368 a...

Page 112: ...Drivetrain CT Repair wc_tx000554gb fm 112 Notes...

Page 113: ...5 ml 17380 50 ml Loctite 271 277 Hernon 427 Omnifit 1550 220M Red High strength for all threads up to 25 mm 1 Heat parts before disassembly Temp range 54 to 149 C 65 to 300 F 29312 5 ml 26685 10 ml 7...

Page 114: ...ts follow instructions on container The sealants listed are recommended for use on Wacker equipment TYPE Europe COLOR USAGE PART NO SIZE Loctite 496 Hernon 110 Omnifit Sicomet 7000 Clear Instant adhes...

Page 115: ...5 M4 2 9 26 4 1 36 4 9 43 7 9 32 3 M5 6 0 53 8 5 6 10 7 8 5 16 4 M6 10 7 14 10 17 13 10 5 M8 25 18 35 26 41 30 13 1 2 6 M10 49 36 69 51 83 61 17 11 16 8 M12 86 63 120 88 145 107 19 3 4 10 M14 135 99 1...

Page 116: ...8 2 5 22 3 5 31 4 7 42 9 11 32 9 64 No 10 3 6 32 5 1 45 6 8 60 3 8 5 32 1 4 8 1 6 12 9 16 12 7 16 3 32 5 16 18 13 26 19 33 24 13 1 2 1 4 3 8 31 23 45 33 58 43 9 16 5 16 7 16 50 37 71 52 94 69 16 5 8...

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Page 118: ...02 0 Fax 49 0 89 3 54 02 3 90 Wacker Corporation P O Box 9007 Menomonee Falls WI 53052 9007 Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 Wacker Asia Pacific Operations Skyline Tower Suite 2303 2...