www.wackergroup.
CRT Repair Foreword This manual covers machines with Item Number: 0009086, 0009216, 0009232, 0009481, 0009482, 0009483 Operating / Parts Information You must be familiar with the operation of this machine before you attempt to troubleshoot or repair it. Basic operating and maintenance procedures are described in the Operator’s Manual supplied with the machine. Keep a copy of the Operator’s Manual with the machine at all times.
Foreword WARNING CRT Repair CALIFORNIA Proposition 65 Warning: Engine exhaust, some of its constituents, and certain vehicle components, contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. All rights, especially copying and distribution rights, are reserved.
CRT Repair 1. Safety Information 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2. Operating Safety .................................................................................. 5 Operator Safety while using Internal Combustion Engines .................. 6 Service Safety ...................................................................................... 7 Label Locations—CRT 36 .................................................................... 8 Label Locations—CRT 48 (manual steer) ..............................
Table of Contents 4.10 4.11 4.12 4.13 4.14 5. 48 Belt Replacement ................................................................................48 Drive Line Teardown and Rebuild .......................................................50 Spiders and Gearboxes 6.1 6.2 6.3 6.4 6.5 6.6 6.7 7. Air Cleaner—CRT 36 ..........................................................................42 Air Cleaner—CRT 48 ..........................................................................43 Engine Oil—CRT 36 ....
CRT Repair 7.21 7.22 7.23 7.24 7.25 7.26 7.27 7.28 7.29 7.30 8. Table of Contents Error Code 311—Right Joystick Open Circuit .................................. 107 Error Code 312—Right Joystick Short Circuit .................................. 110 Error Code 321—Left Joystick Open Circuit .................................... 114 Error Code 322—Left Joystick Short Circuit ..................................... 117 Error Code 414—Control Board Overtemperature ...........................
Safety Information 1. CRT Repair Safety Information This manual contains DANGER, WARNING, CAUTION, and NOTE callouts which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
CRT Repair 1.1 Operating Safety WARNING wc_si000175gb.fm Safety Information Familiarity and proper training are required for the safe operation of equipment. Equipment operated improperly or by untrained personnel can be dangerous. Read the operating instructions contained in both this manual and the engine manual and familiarize yourself with the location and proper use of all controls.
Safety Information 1.2 Operator Safety while using Internal Combustion Engines DANGER wc_si000175gb.fm CRT Repair Internal combustion engines present special hazards during operation and fueling. Read and 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. 1.2.
CRT Repair 1.3 Safety Information Service Safety Poorly maintained equipment can become a safety hazard! In order for the equipment to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. WARNING wc_si000175gb.fm 1.3.1 DO NOT attempt to clean or service the machine while it is running. Rotating parts can cause severe injury. 1.3.2 DO NOT crank a flooded engine with the spark plug removed on gasoline-powered engines.
Safety Information 1.4 wc_si000175gb.
CRT Repair wc_si000175gb.
Safety Information 1.5 wc_si000175gb.
CRT Repair wc_si000175gb.
Safety Information 1.6 wc_si000175gb.
CRT Repair wc_si000175gb.
Safety Information 1.7 CRT Repair Safety and Operating Labels Wacker machines use international pictorial labels where needed. These labels are described below: Label Meaning DANGER! No sparks, flames or burning objects near machine. CAUTION! Use only clean, filtered gasoline fuel. Water tank fill. Use only clean water or waterbased retardants. WARNING! Hot surface! DANGER! Engines emit carbon monoxide; operate only in well-ventilated area. Read the Operator’s Manual.
CRT Repair Label Safety Information Meaning WARNING! Cutting hazard. Always replace blade guard! WARNING! Pressurized contents. Do not open when hot! WARNING! Hand injury if caught in moving belt. Always replace beltguard. CAUTION! Lifting point Tie-down point Key switch, engine start: Off On Start Torque battery hold down nuts to 3.4Nm (30 in.lbs.) max. wc_si000175gb.
Safety Information CRT Repair Label Meaning WARNING! Read and understand the supplied Operator’s Manual before operating this machine. Failure to do so increases the risk of injury to yourself or others. Blade pitch control. Turn both controls inward to increase blade pitch. Refer to section Pitch Adjustment. Operator’s Manual must be stored on machine. Replacement Operator’s Manual can be ordered through your local Wacker distributor.
CRT Repair Label Safety Information Meaning Refer to Status Indicator Lights section for explanation of this label. CAUTION! Disconnect battery before removing cover. Replace cover before using the machine. CAUTION! Engine oil pressure is low! Stop the engine and check the oil level. CAUTION! Low voltage! Stop the engine and check the charging system. CAUTION! Coolant Temperature is too high. Stop the engine and check the coolant level.
Safety Information Label CRT Repair Meaning WARNING! Always wear hearing and eye protection when operating this machine. Read the operator's manual for machine information. WARNING! Read and understand the supplied Operator’s Manual before operating this machine. Failure to do so increases the risk of injury to yourself or others. Steering control. Refer to section Steering. CAUTION! Engine oil pressure is low! Stop the engine and check the oil level.
CRT Repair wc_si000175gb.
Technical Data 2. CRT Repair Technical Data 2.1 Engine—CRT 36 Part No. CRT 36A 0009232 CRT 36A-E 0009483 Engine Engine Make Honda Engine Model GX670 Rated Power kW (Hp) 17.9 (24) Displacement cm³ (in³) 670 (41) Spark Plug Electrode Gap NGK ZGR5A DENSO J16CR-U mm (in.) 0.70 (0.028) Engine Speed - full load rpm 3850 Engine Speed - idle rpm 1400 Battery Fuel Fuel Tank Capacity Fuel Consumption V / size type l (gal.) l (qt.)/hr. 12 / 340CCA Regular unleaded gasoline 24.6 (6.5) 9 (9.
CRT Repair 2.2 Technical Data Trowel—CRT 36 Part No. CRT 36A 0009232 Rev. 144 and lower CRT 36A 0009232 Rev. 145 and higher CRT 36A-E 0009483 Rev. 117 and lower CRT 36A-E 0009483 Rev. 118 and higher Trowel Operating Weight Dimensions (L x W x H) mm (in.) Rotor Speed (range) rpm Blade Pitch (range) 410 (905) kg (lbs.
Technical Data 2.3 CRT Repair Sound and Vibration Specifications—CRT 36 The required sound specifications, per Appendix 1, Paragraph 1.7.4.f of the EC-Machine Regulations, are: -the sound pressure level at operator’s location (LpA): 84 dB(A) -the guaranteed sound power level (LWA): 102 dB(A) These sound values were determined according to ISO 3744 for the sound power level (LWA) and ISO 11204 for the sound pressure level (LpA) at the operator’s location.
CRT Repair 2.4 Technical Data Engine—CRT 48 (manual steer) Part No. CRT 48-31V 0009086 CRT 48-31V-E 0009481 Engine Engine Make Vanguard Engine Model DM950G Rated Power kW (Hp) 23.1 (31) Displacement cm³ (in³) 950 (58) Spark Plug Electrode Gap type mm (in.) Champion RC12YC 0.76 (0.030) Engine Speed - full load rpm 4000 Engine Speed - idle rpm 1500 Battery Fuel Fuel Tank Capacity Fuel Consumption V / size type l (gal.) l (gal.)/hr. 12 / BCI G24 Regular unleaded gasoline 24.6 (6.
Technical Data 2.5 CRT Repair Trowel—CRT 48 (manual steer) Part No. CRT 48-31V 0009086 Rev. 145 and lower CRT 48-31V 0009086 Rev. 146 and higher CRT 48-31V-E 0009481 Rev. 120 and lower CRT 48-31V-E 0009481 Rev. 121 and higher Trowel Operating Weight Dimensions (L x W x H) mm (in.) Rotor Speed (range) rpm Blade Pitch (range) 562 (1240) kg (lbs.
CRT Repair 2.6 Technical Data Sound and Vibration Specifications—CRT 48 (manual steer) The required sound specification, Paragraph 1.7.4.f of 89/392/EEC Machinery Directive, is: • the sound pressure level at operator’s location (LpA) 91 dB(A) • the guaranteed sound power level (LWA) 109 dB(A) These sound values were determined according to ISO 3744 for the sound power level (LWA) and ISO 11204 for the sound pressure level (LpA) at the operator’s location.
Technical Data 2.7 CRT Repair Engine—CRT 48 (electric steer) Part No. CRT 48-31V-ES 0009216 CRT 48-31V-ES-E 0009482 Engine Engine Make Vanguard Engine Model DM950G Rated Power kW (Hp) 23.1 (31) Displacement cm³ (in³) 950 (58) Spark Plug Electrode Gap type mm (in.) Champion RC12YC 0.76 (0.030) Engine Speed - full load rpm 4000 Engine Speed - idle rpm 1500 Battery Fuel Fuel Tank Capacity Fuel Consumption V / size type l (gal.) l (gal.)/hr. 12 / Group 24 Regular unleaded gasoline 24.
CRT Repair 2.8 Technical Data Trowel—CRT 48 (electric steer) Part No. CRT 48-31V -ES 0009216 Rev. 118 and lower CRT 48-31V -ES 0009216 Rev. 119 and higher CRT 48-31V -ES-E 0009482 Rev. 118 and lower CRT 48-31V -ES-E 0009482 Rev. 119 and higher Trowel Operating Weight Dimensions (L x W x H) mm (in.) Rotor Speed (range) rpm Blade Pitch (range) 528 (1165) kg (lbs.
Technical Data 2.9 CRT Repair Sound and Vibration Specifications—CRT 48 (electric steer) The required sound specification, Paragraph 1.7.4.f of 89/392/EEC Machinery Directive, is: • the sound pressure level at operator’s location (LpA) 91 dB(A) • the guaranteed sound power level (LWA) 109 dB(A) These sound values were determined according to ISO 3744 for the sound power level (LWA) and ISO 11204 for the sound pressure level (LpA) at the operator’s location.
CRT Repair 3. Operation Operation 3.1 Description The Wacker CRT Model Riding Trowels are modern, high production machines intended for finishing concrete. Finishing rates vary depending on operator skill and job conditions. Available in two models, Wacker CRT Riding Trowels are equipped with heavy-duty gearboxes designed to provide exceptional performance, low maintenance, and trouble-free use in most conditions.
Operation 3.3 CRT Repair Features and Controls—CRT 36/48 Manual Steer a Right pitch control m Work light (one each side) b Water tank n Foot pedal (throttle control) c Control arms o Engine choke control d Operator’s seat with “operator presence” switch q Work light switch e Left pitch control r DC accessory outlet f Rear work light (one each side) s Engine keyswitch g Control panel (one each side) t Hour meter h Fuel tank u Water spray control wc_tx000589gb.
CRT Repair 3.4 Ref. Operation Features and Controls—CRT 48 Electric Steer Description Ref.
Operation 3.5 CRT Repair Before Starting Before starting the trowel, check the following: • fuel level • oil level in the engine • condition of the air filter • condition of trowel arms and blades Grease the trowel arms daily. 3.6 Starting Before starting the operator must know the location and function of all controls. 3.6.1 Push down on the throttle foot pedal, turn the engine keyswitch (s), and hold it until the engine starts.
CRT Repair wc_tx000589gb.
Maintenance 4. CRT Repair Maintenance 4.1 Periodic Maintenance Schedule—CRT 36 The chart below lists basic trowel and engine maintenance. Refer to engine manufacturer’s Operator’s Manual for additional information on engine maintenance. A copy of the engine Operator’s Manual was supplied with the machine when it was shipped. To service the engine, tilt the seat forward. Daily Grease trowel arms. • Check fuel level. • Check engine oil level.1 • Inspect air filter. Replace as needed.
CRT Repair 4.2 Maintenance Periodic Maintenance Schedule—CRT 48 The chart below lists basic trowel and engine maintenance. Refer to engine manufacturer’s Operator’s Manual for additional information on engine maintenance. A copy of the engine Operator’s Manual was supplied with the machine when it was shipped. To service the engine, tilt the seat forward. Daily Grease trowel arms. • Check fuel level. • Check engine oil level.1 • Inspect air filter. Replace as needed.
Maintenance 4.3 CRT Repair Trowel Gearboxes See Graphic: wc_gr000156 Check the gearboxes for the correct oil level after every 20 hours of operation. Change the gearbox oil every 300 hours. To check the oil level: Each CRT gearbox is equipped with two oil fill plugs. Remove one gearbox oil fill plug (b). If the level is below the threads of the oil fill plug hole, add synthetic gear oil through the opening. DO NOT overfill.
CRT Repair 4.4 Maintenance Lubrication See Graphic: wc_gr001253 The drive system, gearbox and pitch posts are equipped with several grease fittings. Grease these fittings once a week, or every 20 hours, to prevent wear. Use a general purpose grease and add one to two shots of grease at each fitting. wc_tx000581gb.
Maintenance 4.5 CRT Repair Switching Blade Positions See Graphic: wc_gr000255 To switch the position of the blades from the non-overlapping position (f) to the overlapping position (g): 4.5.1 Place the trowel on a flat, level surface. 4.5.2 Remove the screws (a) holding the blade to the trowel arm. 4.5.3 CRT 48 only - Remove the plastic plug from the off-set screw hole (b) and place it into screw hole (c) to prevent it from filling with concrete. 4.5.
CRT Repair 4.6 Maintenance Mounting Float Pans See Graphic: wc_gr000275 and wc_gr000151 Certain applications may require the use of float pans. Optional float pans (a) are available, and are used with the machines in the nonoverlapping configuration only. To mount float pans: Lift trowel off the ground with the engine off and position the pan against the blades. Turn pan either to the right or left to engage clip angles (b) as shown.
Maintenance 4.7 CRT Repair Transporting Trowels See Graphic: wc_gr000697 To lift the trowel with a fork lift: Fork lift pockets (a) are provided on both the front and back of the machine. Carefully run the fork lift’s forks into either set of fork lift pockets. To hoist the trowel: Attach a sling or chains through the lifting bars (b) on each side of the seat pedestal. CAUTION: Make sure the lifting device has enough weight-bearing capacity to lift machine safely. Refer to Section Technical Data.
CRT Repair 4.8 Maintenance Spark Plug—CRT 36 Clean or replace spark plug as needed to ensure proper operation. Refer to the engine Owner’s Manual. Recommended Plug: Champion RC12YC WARNING The muffler and engine cylinder become very hot during operation and remain hot for a while after stopping the engine. Allow engine to cool before removing spark plug. 4.8.1 Remove spark plug and inspect it. 4.8.2 Replace plug if the insulator is cracked or chipped. Clean spark plug electrodes with a wire brush.
Maintenance CRT Repair 4.10 Air Cleaner—CRT 36 See Graphic: wc_gr000154 The engine is equipped with a dual element air cleaner. Service air cleaner frequently to prevent carburetor malfunction. CAUTION: NEVER run engine without air cleaner. Severe engine damage will occur. NEVER use gasoline or other types of low flash point solvents for cleaning the air cleaner. A fire or explosion could result. WARNING To service: 4.10.1 Remove air cleaner cover (a).
CRT Repair Maintenance 4.11 Air Cleaner—CRT 48 See Graphic: wc_gr000216 To service: 4.11.1 Unlock clamps (d) and remove cover (c). 4.11.2 Remove cartridge (b) from air cleaner body (a). Clean by gently tapping cartridge. (Replace cartridge if very dirty or damaged.) 4.11.3 Carefully clean out air cleaner cover (c). NEVER use gasoline or other types of low flash point solvents for cleaning the air cleaner. A fire of explosion could result. WARNING 4.11.4 Install cartridge in body 4.11.
Maintenance CRT Repair 4.12 Engine Oil—CRT 36 See Graphic: wc_gr000155 Drain oil while engine is still warm. 4.12.1 Remove oil fill cap (a) and drain plug (b) to drain oil. Note: In the 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 protection legislation. 4.12.2 Install drain plug and tighten. 4.12.
CRT Repair Maintenance 4.13 Engine Oil—CRT 48 See Graphic: wc_gr000217 Drain oil while engine is still warm. 4.13.1 Remove oil fill cap (a) and drain plug (b) to drain oil. Note: In the 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 protection legislation. 4.13.2 Install drain plug and torque to 34.6 Nm (25.5 ft.lbs.). 4.13.
Maintenance CRT Repair 4.14 Basic Troubleshooting Problem Engine does not start. Machine out of balance; wobbling excessively. Machine does not move. wc_tx000581gb.fm Reason Remedy Operator present switch is not engaged. Sit in operator's seat. Oil alert shutdown feature is activated. Add oil to engine. Engine problem. Oil alert shutdown feature is activated. Operator is over-steering.
CRT Repair Problem Machine does not respond correctly to control lever movement. Trowel noisy. wc_tx000581gb.fm Maintenance Reason Remedy Sheared key. Check all keys in drive system. Loose electrical connector on actuator or joystick. Check all connections. Electronic control board failure. Replace electronic control board. Trowel blades have become misaligned and are contacting each other during rotation. Replace damaged blades.
Drive Train 5. CRT Repair Drive Train 5.1 Belt Replacement See Graphic: wc_gr003419 5.1.1 Place the trowel on a flat, level surface with the blades pitched flat. 5.1.2 Disconnect the battery. 5.1.3 Remove the beltguard as follows: For Honda engines: • Remove the bolts holding the beltguard in place and remove it. For Vanguard engines: wc_tx000582gb.fm • Remove the two bolts holding the base of the air cleaner to the beltguard and remove the air cleaner.
CRT Repair Drive Train 50.33±0.76 mm (1.98±0.03 in.) d b 63.5 mm (2.5 in.) c CRT 36: 387.6 mm (15.25 in.) CRT 48-31V: 387.6 mm (15.25 in.) e f a wc_gr003419 wc_tx000582gb.
Drive Train 5.2 CRT Repair Drive Line Teardown and Rebuild See Graphic: wc_gr001580 Disassembly: 5.2.1 Remove the drive belt. Also remove the drive shaft, pulley, and bearing flanges as an assembly. See section Belt Replacement. 5.2.2 Remove the screws (a) from the outside end of both universal joints (c) and remove the universal joints from the gearboxes. 5.2.3 Remove the center bolt (i) and washer (k) from both of the shaft flanges (l).
CRT Repair Drive Train o d e l k i c g m h b a p n f j a b i k d e c h l g wc_gr001580 wc_tx000582gb.
Spiders and Gearboxes 6. CRT Repair Spiders and Gearboxes 6.1 Gearbox Basics See Graphic: wc_gr001579 Rotation of the gearboxes differs depending on which side of the trowel the gearbox is located. When viewed from the operator’s position, gearboxes located on the right-hand side of the trowel rotate counterclockwise; gearboxes on the left-hand side of the trowel rotate clockwise.
CRT Repair wc_tx000583gb.
Spiders and Gearboxes 6.2 CRT Repair Gearbox Removal and Installation See Graphic: wc_gr003420 and wc_gr003421 This procedure requires a lift or crane capable of lifting the trowel 562 kgs. (1240 lbs.). 6.2.1 Position the trowel on a flat, level surface large enough for the trowel and capable of supporting the weight of the trowel. 6.2.2 Pitch the blades so they lie flat. 6.2.3 Disconnect the battery. Removal: 6.2.4 6.2.5 Preliminary steps for the right-side gearbox: • Drain the water tank (a).
CRT Repair Spiders and Gearboxes 6.2.9 Remove the bolts (k) and washers securing the bearing flanges (l) on each gearbox. 6.2.10 Using an appropriate lifting crane or hoist, carefully and slowly lift the trowel off the gearbox(es) (m). WARNING 6.2.11 During lifting, the trowel will be unbalanced and could swing. Be sure to have an additional person to guide the trowel. Remove the spiders from the gearboxes. See section Spider Removal and Installation.
Spiders and Gearboxes CRT Repair Installation: 6.2.12 Install the spiders to the gearboxes. See section Spider Removal and Installation. 6.2.13 Position the gearboxes underneath the trowel. 6.2.14 Align the bolt holes with the bearing flanges (l). Secure the bearing flanges to the gearboxes with bolts (k) and washers. Torque the bolts to 86 Nm (63 ft.lbs.). 6.2.15 Secure the pitch control assemblies (i) to the machine. 6.2.16 Secure the pitch control cables (h) to the yokes. 6.2.
CRT Repair Spiders and Gearboxes n k l l j i h l k m wc_gr003421 wc_tx000583gb.
Spiders and Gearboxes 6.3 CRT Repair Spider Removal and Installation See Graphic: wc_gr003422 Removal: 6.3.1 Remove the gearbox(es) from the machine. See section Gearbox Removal and Installation. 6.3.2 Remove the screws that secure the blades to the arms and remove the blades CAUTION wc_tx000583gb.fm The blades may have sharp edges that can cut. Wear an appropriate pair of gloves when removing the blades. 6.3.
CRT Repair Spiders and Gearboxes a h m n b c l k j d e j k i g f l h wc_gr003422 wc_tx000583gb.
Spiders and Gearboxes CRT Repair Installation: 6.3.10 Position the lift ring assembly (n) onto the gearbox. 6.3.11 Place the spider (m) onto the lift ring assembly and secure it with the bolt (k) and washer (l). Install the plug (j) to the spider. 6.3.12 Install the blade yoke (h) with the pivot pin (g) and the cotter pin (f). Install the roller guides (i) if they were removed. When installing the roller guides, use Loctite 271 or an equivalent on the bolt.
CRT Repair Spiders and Gearboxes a h m n b c l k j d e j k i g f l h wc_gr003422 wc_tx000583gb.
Spiders and Gearboxes 6.4 CRT Repair Lift Ring Disassembly and Assembly See Graphic: wc_gr003424 Disassembly: 6.4.1 Remove the gearbox. See section Gearbox Removal and Installation. 6.4.2 Remove the spider. See section Spider Removal and Installation. 6.4.3 Remove the lift ring assembly (a) from the spider. 6.4.4 Clamp the lift ring assembly securely in a vise and remove the lift cap (b) by unthreading it. 6.4.5 Remove the seal ring (c) and the bearing holder (d). 6.4.
CRT Repair Spiders and Gearboxes b g g f b c d x a e g wc_gr003424 wc_tx000583gb.
Spiders and Gearboxes 6.5 CRT Repair Adjusting Blade Angle See Graphic: wc_gr003425 There are two methods that may be used to determine blade pitch. The angle gauge method is recommended. The alternative to the angle gauge method is the combination square method. Angle gauge method (1): 6.5.1 Set the trowel on a flat surface and install the new blades. 6.5.2 Turn the blade pitch controls until the blades are at one-half the maximum pitch. 6.5.
CRT Repair Spiders and Gearboxes 1 2 a d b c wc_gr003425 wc_tx000583gb.
Spiders and Gearboxes 6.6 CRT Repair Gearbox Disassembly See Graphic: wc_gr003426 This procedure requires a hammer-type gear puller. 6.6.1 Remove the gearbox from the machine. See section Gearbox Removal and Installation. 6.6.2 Remove the spider assembly from the gearbox. See section Spider Removal and Installation. 6.6.3 Remove the drain plug (a) and allow the oil to drain out of the gearbox. It may be necessary to remove the oil fill plug (b) to facilitate draining.
CRT Repair Spiders and Gearboxes i c j l k t p o m x q n u w v s b g h r e f d a v p p o n wc_gr003426 wc_tx000583gb.
Spiders and Gearboxes 6.7 CRT Repair Gearbox Assembly See Graphic: wc_gr003427 wc_tx000583gb.fm 6.7.1 Install two new seals (v) into the gearbox. 6.7.2 Press the outer bearing races into the gearbox and the gearbox cover. 6.7.3 Press the bearings (r, s) onto the input shaft (n). 6.7.4 Oil the bearings on the input shaft and place the input shaft into the gearbox. 6.7.5 Press the lower bearing (q) onto the output shaft (m). 6.7.
CRT Repair Spiders and Gearboxes i c j l k p o m x v q w n u s b h r e g a f d v x v wc_gr003427 wc_tx000583gb.
Steering and Pitch Control 7. CRT Repair Steering and Pitch Control 7.1 Pitch Control Removal and Installation See Graphic: wc_gr001585 Removal: 7.1.1 Turn off the machine. 7.1.2 Adjust the pitch on the blades so that they lie flat. 7.1.3 Disconnect the wiring to the front light. 7.1.4 Disconnect the pitch cable (g) from the lift yoke (m) by removing the locknut (t). 7.1.5 Remove the screws (a) and the nuts (b) securing the pitch control and lift the pitch control from the machine. 7.1.
CRT Repair 7.1.16 Steering and Pitch Control Apply Loctite 243 or an equivalent to the screws (a) and install the pitch control tube labeled “L” on the left-side gearbox pivot and the pitch control tube labeled “R” on the right-side gearbox pivot. Torque the screws to 25 Nm (18 ft.lbs.). Note: Left and Right are defined from the operator’s position. 7.1.17 Insert the threaded end of the pitch cable into the pitch cable mount (l).
Steering and Pitch Control 7.2 CRT Repair Removing and Installing the Manual Steering System—CRT 36 See Graphic: wc_gr003443 Removal: 7.2.1 Turn off the machine and disconnect the battery. 7.2.2 Unplug the wiring harness (a). 7.2.3 Remove the bolts (b) securing the steering levers (d) to the handle mounts (c) and remove the steering levers. 7.2.4 Remove the screws from the front grill and remove the front grill.
CRT Repair Steering and Pitch Control Honda (manual) d y r q a t k h l j i g s z m aa o y r q s n z v g t i h b u aa c l j x k w f d wc_tx000584gb.
Steering and Pitch Control 7.3 CRT Repair Removing and Installing the Manual Steering System—CRT 48 See Graphic: wc_gr003443, wc_gr003444 Removal: 7.3.1 Turn off the machine and disconnect the battery. 7.3.2 Unplug the wiring harness (a). 7.3.3 Remove the bolts (b) securing the steering levers (d) to the handle mounts (c) and remove the steering levers. 7.3.4 Remove the screws from the front grill and remove the front grill.
CRT Repair Steering and Pitch Control Vanguard (manual steering) d y r q a t k h l j i g s z m aa q o y r s n v z b g c u i t h b aa x c w l j k f d wc_tx000584gb.
Steering and Pitch Control 7.4 CRT Repair Adjusting Control Arm Pitch (forward or backward) See Graphic: wc_gr003458 For most operators, the optimum position for the control arms (f) is for them to lean (pitch) forward slightly—approximately 5°. Both control arms should lean forward the same amount. To adjust the position of the control arms, carry out the following procedure: 7.4.1 Loosen the jam nuts (b). 7.4.2 Turn the vertical linkage (a) as follows: 7.4.3 7.
CRT Repair Steering and Pitch Control g h i a b s f r q t v c d e a b a b v y d c w e d x wc_tx000584gb.
Steering and Pitch Control 7.6 CRT Repair Adjusting Steering Arm Responsiveness See Graphic: wc_gr003458 The responsiveness of the steering arms can be adjusted by changing the connection point where the adjustable links (a) are mounted to the steering pivots (r). The connection point of the adjustable links can be moved between the front and the rear mounting holes (q) of the steering pivot.
CRT Repair Steering and Pitch Control g h i a b s f r q t v c d e a b a b v y d c w e d x wc_tx000584gb.
Steering and Pitch Control 7.7 CRT Repair Centering the Steering Arms See Graphic: wc_gr003458 The pivot bracket (v) is the connection point between the gearbox and the control arm. When the machine is at rest, the pivot bracket must be in a horizontal position and the right control arm should be in a vertical position 90° to the pivot bracket. Adjusting the steering arms in this manner is referred to as centering the steering arms. To center the steering arms, carry out the following procedure: 7.7.
CRT Repair 7.8 Ref. Steering and Pitch Control Adjustment Values for the Manual Steering System Description Ref. Description a Tilts down 5° when steering handles are tilted towards seat e CRT 48: 13.97 cm (5-1/2 in.) CRT 36: 12.70 cm (5 in.) between center lines of tie-rods b 16.83 cm (6-5/8 in.) between center lines of tie-rods f Tilt steering handles towards seat: 5° Spread steering handles towards rotors: CRT 48: 2°–3° CRT 36: 4°–5° c 15.88 cm (6-1/4 in.
Steering and Pitch Control 7.9 CRT Repair Electric Steering System Background See Graphic: wc_gr003372 Movement of the trowel is dependent on the angle of the gearboxes. The actuators are the mechanical devices which adjust the angle of each gearbox. An electric motor mounted to each actuator spins and as it does it turns the actuator’s main drive screw in or out. This movement of the actuator’s main drive screw changes the angle of the gearbox.
CRT Repair Steering and Pitch Control 2.5V 5.0V 2.5V 0.5V LJS 0.5V 0–5V 5V 2.5V 5.0V RJS RJS 0.5V 12V 5V 5.0V 0–5V 5V 0–5V L3 0–5V 12V L1 M3 M1 C1 P1 P2 L2 M2 0–5V 12V wc_gr003372 Ref. Description M1 Right actuator motor L1 Right load pin M2 Side actuator motor L2 Side load pin M3 Left actuator motor L3 Left load pin P1 Gray, control board connector C1 Control board P2 Black, control board connector LJS Left joystick --- RJS Right joystick - wc_tx000584gb.
Steering and Pitch Control CRT Repair 7.10 “Limp Home” Mode a wc_gr003380 During normal operation, the green status indicator light (a) will remain on. When the green status indicator light flashes, this indicates the trowel is operating in the “limp home” mode. The “limp home” mode signifies a fault with the load pin(s). In the “limp home” mode, the load pins no longer provide feedback to the microprocessor.
CRT Repair Steering and Pitch Control The sequence will repeat as long as there is a fault present. During a multiple-fault condition, the error codes will flash in order of fault priority. After the first fault is corrected, the error code for the second fault will flash and so on, until all faults are corrected. Ref. Description Ref.
Steering and Pitch Control CRT Repair 7.12 Error Code 111—Right Actuator Fault A right actuator fault may be caused by faulty wiring to the actuator motor, a loose actuator jam nut, a faulty actuator motor, or a malfunctioning control board. 7.12.1 Check the condition of the wiring and wire connections at the actuator motor. If necesary, check the continuity of the wiring between the control board and the actuator motor. If the wiring is OK, continue. 7.12.2 Turn the ignition switch ON.
CRT Repair 7.12.5 Steering and Pitch Control Secondly, with the actuator motor still disconnected, connect your multimeter between the orange wire of the wiring harness and ground. Turn the ignition switch ON. Move the right joystick to the full-forward, center, and full-reverse positions. The multimeter should read battery voltage in one of the positions, but read 0 (zero) Volts in the center and opposite position. Perform the same test on the black wire; the readings should be reversed.
Steering and Pitch Control CRT Repair 7.13 Error Code 121—Side Actuator Fault A side actuator fault may be caused by faulty wiring to the actuator motor, a loose actuator jam nut, a faulty actuator motor, or a malfunctioning control board. 7.13.1 Check the condition of the wiring and wire connections at the actuator motor. If necesary, check the continuity of the wiring between the control board and the actuator motor. If the wiring is OK, continue. 7.13.2 Turn the ignition switch ON.
CRT Repair 7.13.5 Steering and Pitch Control Secondly, with the actuator motor still disconnected, connect your multimeter between the orange wire of the wiring harness and ground. Turn the ignition switch ON. Move the right joystick to the full forward, center, and to the full-reverse positions. The multimeter should read battery voltage in one of the positions, but read 0 (zero) Volts in the center and opposite position. Perform the same test on the black wire; the readings should be reversed.
Steering and Pitch Control CRT Repair 7.14 Error Code 131—Left Actuator Fault A left actuator fault may be caused by faulty wiring to the actuator motor, a loose actuator jam nut, a faulty actuator motor, or a malfunctioning control board. 7.14.1 Check the condition of the wiring and wire connections at the actuator motor. If necesary, check the continuity of the wiring between the control board and the actuator motor. If the wiring is OK, continue. 7.14.2 Turn the ignition switch ON.
CRT Repair 7.14.5 Steering and Pitch Control Secondly, with the actuator motor still disconnected, connect your multimeter between the orange wire of the wiring harness and ground. Turn the ignition switch ON. Move the left joystick to the full-forward, center, and full-reverse positions. The multimeter should read battery voltage in one of the positions, but read 0 (zero) Volts in the center and opposite position. Perform the same test on the black wire; the readings should be reversed.
Steering and Pitch Control CRT Repair 7.15 Error Code 211—Right Load Pin Open Circuit See Graphic: wc_gr003376 7.15.1 Check the wire connections at the load pin (L1) and at the control board connector (P2). Reconnect the wiring if needed. If the fault condition remains, continue. 7.15.2 Check the continuity of the wiring between the control board and the load pin. To do so, disconnect the P2 connector from the control board and the L1 connector from the load pin.
CRT Repair 7.15.3 Steering and Pitch Control Check if battery voltage is being sent to the load pin from the control board. To do so, turn the ignition switch ON, connect the black lead of a multimeter to a common ground, and back probe the #1 terminal of the P2 connector with the red lead of the multimeter. The multimeter should read battery voltage (approximately 12VDC). • If no voltage is present, the control board has failed; replace it. • If battery voltage is present, continue.
Steering and Pitch Control CRT Repair 7.16 Error Code 212—Right Load Pin Short Circuit 7.16.1 Check the wire connections at the load pin (L1) and at the control board connector (P2). Reconnect the wiring if needed. If the fault condition remains, continue. 7.16.2 Check the continuity of the wiring between the control board and the load pin. To do so, disconnect the P2 connector from the control board and the L1 connector from the load pin.
CRT Repair 7.16.3 Steering and Pitch Control Check if battery voltage is being sent to the load pin from the control board. To do so, turn the ignition switch ON, connect the black lead of a multimeter to a common ground, and back probe the #1 terminal of the P2 connector with the red lead of the multimeter. The multimeter should read battery voltage (approximately 12VDC). • If no voltage is present, the control board has failed; replace it. • If battery voltage is present, continue.
Steering and Pitch Control 7.16.5 CRT Repair Check if voltage is being leaked through the load pin’s ground wire. To do so, disconnect the wiring harness at P2. Remove the orange locking plug (a) from the front of the connector. Use a small screwdriver to release the locking tab and remove the wire to terminal #3. Do not allow the wire to contact any metal surface. Reinstall the orange locking plug and reconnect the connector to the control board at P2.
CRT Repair Steering and Pitch Control 7.17 Error Code 221—Side Load Pin Open Circuit 7.17.1 Check the wire connections at the load pin (L2) and at the control board connector (P2). Reconnect the wiring if needed. If the fault condition remains, continue. 7.17.2 Check the continuity of the wiring between the control board and the load pin. To do so, disconnect the P2 connector from the control board and the L2 connector from the load pin.
Steering and Pitch Control 7.17.3 CRT Repair Check if battery voltage is being sent to the load pin from the control board. To do so, turn the ignition switch ON, connect the black lead of a multimeter to a common ground, and back probe the #4 terminal of the P2 connector with the red lead of the multimeter. The multimeter should read battery voltage (approximately 12VDC). • If no voltage is present, the control board has failed; replace it. • If battery voltage is present, continue.
CRT Repair Steering and Pitch Control 7.18 Error Code 222—Side Load Pin Short Circuit 7.18.1 Check the wire connections at the load pin (L2) and at the control board connector (P2). Reconnect the wiring if needed. If the fault condition remains, continue. 7.18.2 Check the continuity of the wiring between the control board and the load pin. To do so, disconnect the P2 connector from the control board and the L2 connector from the load pin.
Steering and Pitch Control 7.18.3 CRT Repair Check if battery voltage is being sent to the load pin from the control board. To do so, turn the ignition switch ON, connect the black lead of a multimeter to a common ground, and back probe the #4 terminal of the P2 connector with the red lead of the multimeter. The multimeter should read battery voltage (approximately 12VDC). • If no voltage is present, the control board has failed; replace it. • If battery voltage is present, continue.
CRT Repair 7.18.5 Steering and Pitch Control Check if voltage is being leaked through the load pin’s ground wire. To do so, disconnect the wiring harness at P2. Remove the orange locking plug (a) from the front of the connector. Use a small screwdriver to release the locking tab and remove the wire to terminal #6. Reinstall the orange locking plug and reconnect the connector to the control board at P2. Turn the ignition ON and check for voltage between the wire and ground. There should be no voltage.
Steering and Pitch Control CRT Repair 7.19 Error Code 231—Left Load Pin Open Circuit 7.19.1 Check the wire connections at the load pin (L3) and at the control board connector (P2). Reconnect the wiring if needed. If the fault condition remains, continue. 7.19.2 Check the continuity of the wiring between the control board and the load pin. To do so, disconnect the P2 connector from the control board and the L3 connector from the load pin.
CRT Repair 7.19.3 Steering and Pitch Control Check if battery voltage is being sent to the load pin from the control board. To do so, turn the ignition switch ON, connect the black lead of a multimeter to a common ground, and back probe the #7 terminal of the P2 connector with the red lead of the multimeter. The multimeter should read battery voltage (approximately 12VDC). • If no voltage is present, the control board has failed; replace it. • If battery voltage is present, continue.
Steering and Pitch Control CRT Repair 7.20 Error Code 232—Left Load Pin Short Circuit 7.20.1 Check the wire connections at the load pin (L3) and at the control board connector (P2). Reconnect the wiring if needed. If the fault condition remains, continue. 7.20.2 Check the continuity of the wiring between the control board and the load pin. To do so, disconnect the P2 connector from the control board and the L3 connector from the load pin.
CRT Repair 7.20.3 Steering and Pitch Control Check if battery voltage is being sent to the load pin from the control board. To do so, turn the ignition switch ON, connect the black lead of a multimeter to a common ground, and back probe the #7 terminal of the P2 connector with the red lead of the multimeter. The multimeter should read battery voltage (approximately 12VDC). • If no voltage is present, the control board has failed; replace it. • If battery voltage is present, continue.
Steering and Pitch Control 7.20.5 CRT Repair Check if voltage is being leaked through the load pin’s ground wire. To do so, disconnect the wiring harness at P2. Remove the orange locking plug (a) from the front of the connector. Use a small screwdriver to release the locking tab and remove the wire to terminal #9. Do not allow the wire to contact any metal surface. Reinstall the orange locking plug and reconnect the connector to the control board at P2.
CRT Repair Steering and Pitch Control 7.21 Error Code 311—Right Joystick Open Circuit 7.21.1 Check the wire connections at the joystick and at the control board connector (P1). Reconnect the wiring if needed. If the fault condition remains, continue. 7.21.2 Check the continuity of the wiring between the control board and the joystick. To do so, disconnect the P1 connector from the control board and the wiring connector from the joystick.
Steering and Pitch Control 7.21.3 CRT Repair Check for voltage at the P1 control board connector. To do so, turn the ignition switch ON, connect the black lead of a multimeter to a common ground, and back probe the #2 terminal of the P1 connector with the red lead of the multimeter.The multimeter should read 5.0±0.2 Volts. • If no voltage is measured, the control board has failed; replace it. • If voltage is measured,continue. P1 2 wc_gr003400 7.21.
CRT Repair 7.21.5 Steering and Pitch Control Check for feedback voltage (side-to-side operation) from the joystick at the P1 control board connector. To do so, turn the ignition switch ON, connect the black lead of the multimeter to a common ground, and back probe the #4 terminal of the P1 connector. With the right joystick in the centered position, 2.5±0.2 Volts should be measured. • If no voltage is measured, the right joystick has failed; replace it. • If proper voltage is measured, continue.
Steering and Pitch Control CRT Repair 7.22 Error Code 312—Right Joystick Short Circuit 7.22.1 Check the wire connections at the joystick and at the control board connector (P1). Reconnect the wiring if needed. If the fault condition remains, continue. 7.22.2 Check the continuity of the wiring between the control board and the load pin. To do so, disconnect the P1 connector from the control board and the wiring connector from the joystick.
CRT Repair 7.22.3 Steering and Pitch Control Check for voltage at terminal #2 of the P1 control board connector. To do so, turn the ignition switch ON, connect the black lead of a multimeter to a common ground, and back probe the #2 terminal of the P1 connector with the red lead of the multimeter. With the right joystick in the centered position, approximately 5.0 Volts should be measured. • If no voltage is measured, the control board has failed; replace it.
Steering and Pitch Control 7.22.5 CRT Repair Check the feedback voltage at terminal #4 of the P1 control board connector. To do so, turn the ignition switch ON, connect the black lead of the multimeter to a common ground, and back probe the #4 terminal of the P1 connector with the red lead. With the right joystick in the centered position, approximately 2.5V should be measured. • If more than 2.8V is measured, the right joystick has failed; replace it. • If the proper voltage is measured, continue.
CRT Repair 7.22.7 Steering and Pitch Control Check the joystick ground wire. To do so, disconnect the wiring harness at P1. Remove the orange locking plug (a) from the front of the connector. Use a small screwdriver to release the locking tab and remove the black wire from terminal #6. Isolate the black wire from all metal surfaces. Reinstall the orange locking plug and reconnect the connector to the control board at P1. Turn the ignition ON and check for voltage between the black wire and ground.
Steering and Pitch Control CRT Repair 7.23 Error Code 321—Left Joystick Open Circuit 7.23.1 Check the wire connections at the joystick and at the control board connector (P1). Reconnect the wiring if needed. If the fault condition remains, continue. 7.23.2 Check the continuity of the wiring between the control board and the joystick. To do so, disconnect the P1 connector from the control board and the wiring connector from the joystick.
CRT Repair 7.23.3 Steering and Pitch Control Check for voltage at terminal #7 of the P1 control board connector. To do so, turn the ignition switch ON, connect the black lead of a multimeter to a common ground, and back probe the #7 terminal of the P1 connector with the red lead of the multimeter. With the left joystick in the centered position, the multimeter should read approximately 5 Volts. • If no voltage is measured, the control board has failed; replace it. • If voltage is measured,continue.
Steering and Pitch Control 7.23.5 CRT Repair Check the joystick ground wire. To do so, disconnect the wiring harness at P1. Remove the orange locking plug (a) from the front of the connector. Use a small screwdriver to release the locking tab and remove the black wire from terminal #10. Isolate the black wire from all metal surfaces. Reinstall the orange locking plug and reconnect the connector to the control board at P1. Turn the ignition ON and check for voltage between the black wire and ground.
CRT Repair Steering and Pitch Control 7.24 Error Code 322—Left Joystick Short Circuit 7.24.1 Check the wire connections at the joystick and at the control board connector (P1). Reconnect the wiring if needed. If the fault condition remains, continue. 7.24.2 Check the continuity of the wiring between the control board and the joystick. To do so, disconnect the P1 connector from the control board and the wiring connector from the joystick.
Steering and Pitch Control 7.24.3 CRT Repair Check for voltage at terminal #7 of the P1 control board connector. To do so, turn the ignition switch ON, connect the black lead of a multimeter to a common ground, and back probe the #7 terminal of the P1 connector with the red lead of the multimeter.The multimeter should read approximately 5.0V. • If no voltage is measured, the control board has failed; replace it. • If the proper voltage is measured,continue. P1 7 wc_gr003408 7.24.
CRT Repair 7.24.5 Steering and Pitch Control Check the joystick ground wire. To do so, disconnect the wiring harness at P1. Remove the orange locking plug (a) from the front of the connector. Use a small screwdriver to release the locking tab and remove the black wire from terminal #10. Isolate the black wire from all metal surfaces. Reinstall the orange locking plug and reconnect the connector to the control board at P1. Turn the ignition ON and check for voltage between the black wire and ground.
Steering and Pitch Control CRT Repair 7.25 Error Code 414—Control Board Overtemperature If a control board over-temperature condition occurs, shutdown the machine and allow the control board to cool to ambient temperature. Inspect the area surrounding the control board and remove any accumulated debris. After the machine has cooled, attempt to run the machine. If the error code reappears, replace the control panel. wc_tx000584gb.
CRT Repair Steering and Pitch Control 7.26 Error Code 414—Control Board Overtemperature If a low battery condition occurs, shutdown the machine. wc_tx000584gb.fm • Inspect the battery and the wiring harness. • Remove any corrosion from the battery terminals. • Inspect the wiring for the actuator motors at the control panel. Remove any corrosion from the wiring. • Check the 50A and 70A maxi-fuses. Remove any corrosion from the fuse connectors. • Load test the battery.
Steering and Pitch Control CRT Repair 7.27 Removal and Installation of Actuator Load Pins See Graphic: wc_gr003445 Removal: 7.27.1 Turn the key switch to the OFF position. 7.27.2 The trowel should be on a flat surface with the blades pitched flat. 7.27.3 For the rear actuator (left/right steering), remove the protective cover (a). 7.27.4 Disconnect the load pin wiring connector (b). 7.27.5 Remove the retaining ring (c) from the shaft. 7.27.
CRT Repair Steering and Pitch Control e c d e c d a b e d c wc_gr003445 wc_tx000584gb.
Steering and Pitch Control CRT Repair 7.28 Removal and Installation of Actuators See Graphic: wc_gr003446 Removal: 7.28.1 Turn off the machine. 7.28.2 Remove lower actuator mounting bolt or pin (a). 7.28.3 Remove the load pin (b) and carefully remove the actuator (c) from the machine. See section Removal and Replacement of Actuator Load Pins. Installation: The actuator length should be checked every time the actuator is removed from the machine. Adjust the actuator length before installation.
CRT Repair Steering and Pitch Control b b c c a a 237,5±0,8 mm 9.35±0.03 in. 168,3±0,8 mm 6.625±0.03 in. b e g d a f wc_tx000584gb.
Steering and Pitch Control CRT Repair 7.29 Removal and Installation of Joysticks See Graphic: wc_gr003447 Removal: 7.29.1 Disconnect the battery. 7.29.2 Remove the screws (a) that secure the joystick assembly to the machine and lift the joystick assembly off. Note: The joystick will still be connected to the machine by the wiring harness (b). 7.29.3 Unplug the wiring harness from the joystick. 7.29.4 Remove the screws (c), washers, and nuts that secure the joystick in the housing. 7.29.
CRT Repair Steering and Pitch Control c a e d B R (W) Gr L b wc_gr003447 wc_tx000584gb.
Steering and Pitch Control CRT Repair 7.30 Removal and Installation of Electric Steer Control Board See Graphic: wc_gr003441 Removal: 7.30.1 Disconnect the battery. 7.30.2 Disconnect the gray and black connectors (a and b) from the control board. 7.30.3 Remove the nuts securing the protective cover (c) and remove the protective cover. 7.30.4 Label the motor control wires before disconnecting them from the control board. Once labelled, remove the motor control wires from the control board. 7.30.
CRT Repair Steering and Pitch Control e d a b c wc_gr003441 wc_tx000584gb.
Engine Troubleshooting and Replacement 8. CRT Repair Engine Troubleshooting and Replacement 8.1 Vanguard Engine Does Not Crank—Flowchart 1A Check battery voltage. Is battery fully charged? Recharge or replace battery. No Yes * Battery voltage approximately 12V Check fuse near battery. See Checking 70A Fuse. Is 70A fuse OK? Replace fuse. No Yes Check voltage to starter motor. . See Checking Voltage to Starter Motor.
CRT Repair 8.2 Engine Troubleshooting and Replacement Checking 70A Fuse See Graphic: wc_gr003432 There are two 70A fuses in the electrical system. One of the fuses protects the electric steer circuit; the other protects the engine starting circuit. To check the 70A fuse that protects the engine starting circuit, carry out the following procedure: 8.2.1 Remove the screws that secure the battery cover (a). 8.2.2 Remove the protective cover that protects the fuse (b). 8.2.
Engine Troubleshooting and Replacement 8.3 CRT Repair Checking Voltage to Starter Motor See Graphic: wc_gr003435 Battery voltage is provided directly to the starter motor via the red wire (a). Check that the red wire is securely fastened to the starter motor. Battery voltage is also provided to the starter solenoid via the black wire (b) when the ignition switch is in the START position. This wire has a female spade connector. Check that it is connected securely to the starter solenoid.
CRT Repair 8.4 Engine Troubleshooting and Replacement Checking Ignition Switch See Graphic: wc_gr003434 The ignition switch may be checked either installed into or removed from the control panel. Check the continuity between each terminal when the ignition switch is in each of its positions: OFF, ON, and START.
Engine Troubleshooting and Replacement 8.5 CRT Repair Vanguard Engine Cranks but does not Start—Flowchart 2A Check wiring to spark plug or ignition coils. Check 15A fuse. Is wiring OK? No See Checking 15A Fuse. Yes Repair wiring. Is 15A fuse OK? No Replace fuse. Yes Check fuel pump operation. See Checking Fuel Pump. Check for 12V* on pink wire at terminal 30 of operator present relay. See Checking Operator Present Relay.
CRT Repair 8.6 Engine Troubleshooting and Replacement Checking Fuel Pump See Graphic: wc_gr003437 The fuel pump (a) is mounted inside the frame on the left hand side. By checking the operation of the fuel pump one can determine quickly if the problem is associated with the machine’s circuitry or with the engine itself. When the key switch is in the ON position, power should flow to the fuel pump. When the fuel pump receives electric power, you can hear and feel it run.
Engine Troubleshooting and Replacement 8.7 CRT Repair Checking 15A Fuse See Graphic: wc_gr003436 The 15A fuse (a) protects the electronic control module, the operator presence relay, and the associated components down stream of the operator presence relay—the fuel relay, fuel pump, anti-afterfire solenoid, and the ignition module. If this fuse is blown, the engine will crank but it will not start. To check the 15A fuse, remove the protective cover and pull the fuse from the harness.
CRT Repair 8.8 Engine Troubleshooting and Replacement Checking Operator Presence Relay See Graphic: wc_gr003433 The operator presence relay (a) is located behind a protective cover mounted to the machine frame. Battery voltage is sent to terminals 30 and 85 of the operator presence relay by the key switch via the pink wires. To check the voltage at the operator presence relay, carry out the following procedure: 8.8.1 Remove the protective cover. 8.8.
Engine Troubleshooting and Replacement 8.9 CRT Repair Checking Wiring to and Function of Throttle Switch See Graphic: wc_gr003438 In order for the operator presence relay to energize, the circuit through the coil side of the relay (terminals 85 and 86) must be completed. This is done through the throttle switch. The L/Br wire runs from terminal 86 of the operator presence relay to the throttle switch (and to the operator presence switch).
CRT Repair Engine Troubleshooting and Replacement a b wc_gr003438 wc_tx000585gb.
Engine Troubleshooting and Replacement CRT Repair 8.10 Vanguard Engine Cranks but does not Start—Flowchart 2B Continued from Flowchart 2A Check for 12V* on pink wire at terminals 85 & 30 of fuel relay. See Checking Fuel Relay. Is 12V measured? No Yes Check wiring between key switch and fuel relay. Check 12V* on R/B wire at ignition module. See Checking Ignition Module. Check for 12V* on P/W wire at fuel pump. Is 12V measured? See Checking Fuel Relay. Is 12V measured? Yes Replace fuel pump.
CRT Repair Engine Troubleshooting and Replacement 8.11 Checking Fuel Relay See Graphic: wc_gr003439 The fuel relay (a) is located behind a protective cover mounted to the machine frame. Battery voltage is sent to terminals 30 and 85 of the fuel relay by the key switch via the pink wires. To check the voltage at the fuel relay, carry out the following procedure: 8.11.1 Remove the protective cover. 8.11.2 Cut the wire ties that secure the operator presence relay. 8.11.
Engine Troubleshooting and Replacement CRT Repair 8.12 Checking Ignition Module See Graphic: wc_gr003440 The ignition module (a) is located behind a protective cover mounted to the machine frame. Battery voltage is sent to the ignition module via the P wire connected to the R/B wire from the operator presence relay. To check the voltage at the ignition module, carry out the following procedure: 8.12.1 Remove the protective cover. 8.12.2 Remove the left side connector (b). 8.12.
CRT Repair Engine Troubleshooting and Replacement 8.13 Honda Engine Does Not Crank—Flowchart 3A Check battery voltage. Is battery fully charged? Recharge or replace battery. No Yes * Battery voltage approximately 12V Check voltage to starter motor. . See Checking Voltage to Starter Motor. Is there 12V* to starter motor? Yes Replace starter motor and/or starter motor relay No Check function of ignition switch. See Checking Ignition Switch.
Engine Troubleshooting and Replacement CRT Repair 8.14 Removing the Honda Engine See Graphic: wc_gr003431 This procedure requires a lift or crane capable of lifting 136 kgs. (300 lbs.). 8.14.1 Position the trowel on a flat surface. 8.14.2 Disconnect the battery. 8.14.3 Remove the drive belt. See section Belt Replacement. 8.14.4 Close the fuel valve on the fuel tank. 8.14.5 Disconnect the fuel hose (a) from the fuel filter. 8.14.
CRT Repair Engine Troubleshooting and Replacement a b a b e d c g h f wc_gr003431 wc_tx000585gb.
Engine Troubleshooting and Replacement CRT Repair 8.15 Installing the Honda Engine See Graphic: wc_gr003431 This procedure requires a lift or crane capable of lifting 136 kgs. (300 lbs.). 8.15.1 Position the engine onto the machine’s frame. 8.15.2 Temporarily secure the engine and the battery ground cable to the machine with four bolts from underneath the machine. 8.15.3 Reconnect the three wires of the oil pressure switch harness (h). 8.15.4 Reconnect the throttle (f) and choke cable (g). 8.15.
CRT Repair Engine Troubleshooting and Replacement a b a b e d c g h f wc_gr003431 wc_tx000585gb.
Engine Troubleshooting and Replacement CRT Repair 8.16 Removing the Vanguard Engine See Graphic: wc_gr003428 This procedure requires a lift or crane capable of lifting 136 kgs. (300 lbs.). 8.16.1 Position the trowel on a flat surface. 8.16.2 Disconnect the battery. 8.16.3 Close the fuel valve on the fuel tank. 8.16.4 Remove the drive belt. See section Belt Replacement. 8.16.5 Remove one of the screws that secures the cross brace (a) and swing the cross brace out of the way. 8.16.
CRT Repair Engine Troubleshooting and Replacement a b 3 2 1 m e d f c g j h i n k l wc_gr003428 wc_tx000585gb.
Engine Troubleshooting and Replacement CRT Repair 8.17 Installing the Vanguard Engine See Graphic: wc_gr003428 This procedure requires a lift or crane capable of lifting 136 kgs. (300 lbs.). 8.17.1 Using an appropriate lift or crane, lower the engine (n) into the machine. 8.17.2 Secure the engine to the cradle with the screws (k) on each side of the engine. Install the radiator brackets (l) if removed. Tighten the muffler (m) at the manifold if loosened during engine removal. 8.17.
CRT Repair Engine Troubleshooting and Replacement a b 3 2 1 m e d f c g j h i n k l wc_gr003428 wc_tx000585gb.
Engine Troubleshooting and Replacement CRT Repair 8.18 Wiring Schematic—Honda 86 85 30 87A 87 T T R 86 T 85 87 30 L 87A L W P Or Pr Or L B Pr R W B/Y W Br Pr R B Br Or Y B B/P Gr Gr W Pr G W Br W B 11 Br/Or Br/Or Br/L Br/Or Br 30 NO NC G Br wc_gr003429 wc_tx000585gb.
CRT Repair Engine Troubleshooting and Replacement Honda Motor Ref. Description Ref.
Engine Troubleshooting and Replacement CRT Repair 8.19 Wiring Schematic-Vanguard Engine (manual steer) wc_tx000585gb.
CRT Repair Engine Troubleshooting and Replacement Vanguard Motor (manual steer) Ref. Description Ref.
Engine Troubleshooting and Replacement CRT Repair 8.20 Wiring Schematic-Vanguard Engine (electric steer) wc_tx000585gb.
CRT Repair Engine Troubleshooting and Replacement Vanguard Motor (electric steer) Ref. Description Ref.
Engine Troubleshooting and Replacement Vanguard (electric steer) wc_tx000585gb.
CRT Repair Engine Troubleshooting and Replacement Vanguard Motor (electric steer) Ref. Description Ref.
Engine Troubleshooting and Replacement Notes: wc_tx000585gb.
Threadlockers and Sealants Threadlockers and Sealants Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container. The sealants listed are recommended for use on Wacker equipment.
Threadlockers and Sealants Threadlockers and Sealants (continued) Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container.
Torque Values Torque Values Metric Fasteners (DIN) TORQUE VALUES (Based on Bolt Size and Hardness) 8.8 10.9 WRENCH SIZE 12.9 Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch M3 1.2 *11 1.6 *14 2.1 *19 5.5 7/32 2.5 – M4 2.9 *26 4.1 *36 4.9 *43 7 9/32 3 – M5 6.0 *53 8.
Torque Values Torque Values (continued) Inch Fasteners (SAE) Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch No.4 0.7 *6 1.0 *14 1.4 *12 5.5 1/4 – 3/32 No.6 1.4 *12 1.9 *17 2.4 *21 8 5/16 – 7/64 No.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.
Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 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, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel.
