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CRT Repair Table of Contents 1. Foreword 3 2. Safety Information 6 2.1 2.2 2.3 3. Technical Data 3.1 3.2 3.3 3.4 4. Kohler Engine ..................................................................................... 10 Honda Engine ..................................................................................... 12 Vanguard Engine (manual steer) ....................................................... 14 Vanguard Engine (electric steer) ........................................................
Table of Contents 7. Steering and Pitch Control 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 7.16 7.17 7.18 7.19 7.20 7.21 7.22 7.23 8. CRT Repair 45 Removal and Installation of Manual Steering Yokes ...........................45 Adjustment of Manual Steering ...........................................................49 Pitch Control Removal and Installation ...............................................50 Removal and Installation of Electric Steering Load Pins ....................
CALIFORNIA Proposition 65 Warning: Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California WARNING to cause cancer and birth defects or other reproductive harm. 1. Foreword This manual provides information and procedures to safely operate 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.
Notes: wc_tx000093gb.
This manual covers machines with Item Number: 0009083, 0009084, 0009085, 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 make any repairs to it. Basic operating and maintenance procedures are described in the operator’s manual supplied with the machine. Keep a copy of it with the machine at all times.
Safety Information 2. 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 2.1 Safety Information Operating Safety 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 WARNING this manual and the engine manual and familiarize yourself with the location and proper use of all controls. Inexperienced operators should receive instruction from someone familiar with the equipment before being allowed to operate the machine.
Safety Information 2.2 CRT Repair Operator Safety while using Internal Combustion Engines DANGER Internal combustion engines present special hazards during operation and fueling! Read and follow warning instructions in engine owner's manual and safety guidelines below. Failure to follow warnings and safety guidelines could result in severe injury or death. 2.2.
CRT Repair 2.3 Service Safety WARNING wc_tx000093gb.fm Safety Information 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. 2.3.1 DO NOT attempt to clean or service machine while it is running. Rotating parts can cause severe injury. 2.3.2 DO NOT crank a flooded engine with the spark plug removed on gasoline-powered engines.
Technical Data 3. CRT Repair Technical Data 3.1 Kohler Engine Part No. CRT 48 0009084, 0009085 CRT 36 0009083 Engine Engine Make Kohler Kohler Engine Model CH25 CH23 Rated Power kW (Hp) 18.6 (25) 17.2 (23) Displacement cm³ (in³) 725 (44) 674 (41) Spark Plug Champion RC12YC Electrode Gap mm (in.) 0.76 (0.030) Engine Speed - full load rpm 4000 Engine Speed - idle rpm 1200 Battery V / size Fuel type Fuel Tank Capacity l (gal.) Fuel Consumption l (qt.)/hr.
CRT Repair Technical Data Part No. CRT 48 0009084, 0009085 CRT 36 0009083 Trowel Operating Weight kg (lbs.) 430 (945) 383 (845) Dimensions (L x W x H) mm (in.) 2665 x 1395 x 1330 (105 x 55 x 52) 2170 x 1170 x 1330 (86 x 46 x 52) Rotor Speed (range) rpm CRT48-25K-L: 35-120 CRT48-25K-H: 25-150 35-150 Blade Pitch (range) degrees Gearbox 0-25 heavy duty, fan cooled Gearbox Lubrication* l (oz.) Driveshaft type heavy duty 1.
Technical Data 3.2 CRT Repair Honda Engine 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 NGK ZGR5A DENSO J16CR-U Electrode Gap mm (in.) Engine Speed - full load rpm 3850 Engine Speed - idle rpm 1400 Battery V / size Fuel type Fuel Tank Capacity l (gal.) Fuel Consumption l (qt.)/hr. Running Time hrs. 2.
CRT Repair Technical Data Part No. CRT 36A 0009232 CRT 36A-E 0009483 Trowel Operating Weight kg (lbs.) Dimensions (L x W x H) mm (in.) Rotor Speed (range) rpm Blade Pitch (range) degrees 410 (905) 2170 x 1170 x 1330 (86 x 46 x 52) 2032 x 1170 x 1320 (80 x 46 x 52) 35-150 0-25 Gearbox heavy duty Gearbox Lubrication* l (oz.) Driveshaft type 1.83 (62) each splined universal joint *Use only Mobil Oil SHC634 synthetic oil.
Technical Data 3.3 CRT Repair Vanguard Engine (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 type Electrode Gap mm (in.) Engine Speed - full load rpm 4000 Engine Speed - idle rpm 1500 Battery V / size Fuel type Fuel Tank Capacity l (gal.) Fuel Consumption l (gal.)/hr. Running Time hrs. 2.
CRT Repair Technical Data Part No. CRT 48-31V 0009086 CRT 48-31V-E 0009481 Trowel Operating Weight kg (lbs.) Dimensions (L x W x H) mm (in.) Rotor Speed (range) rpm Blade Pitch (range) degrees 562 (1240) 2665 x 1395 x 1330 (105 x 55 x 52) 2530 x 1397 x 1328 (100 x 55 x 52) 25-150 Gearbox 0-25 heavy duty, fan cooled Gearbox Lubrication* l (oz.) Driveshaft type 1.83 (62) each splined universal joint *Use only Mobil Oil SHC634 synthetic oil.
Technical Data 3.4 CRT Repair Vanguard Engine (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.
CRT Repair Technical Data Part No. CRT 48-31V-ES 0009216 CRT 48-31V-ES-E 0009482 Trowel Operating Weight kg (lbs.) Dimensions (L x W x H) mm (in.) Rotor Speed (range) rpm Blade Pitch (range) degrees 2665 x 1395 x 1330 (105 x 55 x 52) 2530 x 1397 x 1328 (100 x 55 x 52) 25-150 Gearbox Gearbox Lubrication* 528 (1165) 0-25 heavy duty, fan cooled 1.83 (62) each l (oz.) *Use only Mobil Oil SHC634 synthetic oil.
General 4. CRT Repair General 4.
CRT Repair General Kohler or Honda Engine wc_tx000093gb.
General 4.
CRT Repair General Vanguard Engine (manual steer) wc_tx000093gb.
General 4.3 CRT Repair Features and Controls-Vanguard Engine (electric steer) See Graphic: wc_gr000696 Ref. Description Ref.
CRT Repair General Vanguard Engine (electric steer) wc_tx000093gb.
General 4.4 CRT Repair Transporting Trowels See Graphic: wc_gr000144 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 4.5 General Wheel Kit - 0150397 See Graphic: wc_gr002302 Assembling Wheel Kit Components: 4.5.1 Bolt the wheels (b) to the tube assemblies (a) using screws (c), washers (d), and nuts (e) provided. The rigid wheels should be attached perpendicular to the tube assemblies. The lock pin on the swivel casters should be perpendicular to the tube assemblies when attached. 4.5.2 Insert one handle (g) into the other handle (g). 4.5.3 Align the holes. 4.5.
General CRT Repair CAUTION: The weight of the trowel will pivot the wheel and handle, therefore firmly grip the handle. 4.5.17 Pivot the wheel until it locks at 90 degrees. 4.5.18 Remove the handle. 4.5.19 Repeat last four steps for the other wheels. 4.5.20 Remove the retaining pins from the wheel assemblies. 4.5.21 Remove the wheel assemblies from the machine. wc_tx000093gb.
CRT Repair 4.6 General Wheel Kit - 0154750 See Graphic: wc_gr002301 Assembling Wheel Kit Components: 4.6.1 Bolt the wheels (a) to the brackets (b) using screws (c), washers (d), and nuts (e) provided. The rigid wheels should be attached perpendicular to the brackets. 4.6.2 Attach pins (f) to lanyards (g) and jacks (l). 4.6.3 Bolt lanyards to the brackets using screws (h), washers (j), and nuts (k) provided. Raising the CRT: 4.6.4 Insert a screw jack into the square socket in the front of the CRT.
General 4.7 CRT Repair Wheel Kit - 0160259 See Graphic: wc_gr002300 Assembling Wheel Kit Components: 4.7.1 Attach large wheels (a) to the axles (b) using washers (c), and small cotter pins (d) provided. Store wheels on handle using large cotter pins (h). 4.7.2 Attach small wheels (e) to handle using washers (f), and small cotter pins (g) provided. Raising the CRT: 4.7.3 Remove safety snap pin (j) and lengthen handle. Insert safety snap pin (j). 4.7.4 Remove large wheels from handle. 4.7.
CRT Repair wc_tx000093gb.
Drive Line 5. CRT Repair Drive Line 5.1 Belt Replacement See Graphic: wc_gr 000152 To replace the drive belt: 5.1.1 Place the trowel on a flat, level surface with the blades pitched flat. 5.1.2 Disconnect battery. 5.1.3 Remove the beltguard. Honda / Kohler: Remove bolts holding guard in place. Vanguard: Remove two bolts holding base of air cleaner to beltguard. Remove two bolts holding beltguard to engine. wc_tx000094gb.fm 5.1.
CRT Repair 5.2 Drive Line Belt Adjustment 5.2.1 Remove beltguard. 5.2.2 To adjust the tension, loosen the 4 mounting bolts and slide engine forward to loosen; back to tighten. 5.2.3 Maximum belt play should be from 32 mm to 38 mm (1 1/4" to 1 1/2") at the center of the span. Note: Tension on new belts should be checked after the first 10-12 hours of operation. wc_tx000094gb.
Drive Line 5.3 CRT Repair Drive Line Exploded View o d e k l i c g m h b a p n f j a b i k d c e h l g wc_gr001580 wc_tx000094gb.
CRT Repair 5.4 Drive Line Drive Line Teardown and Rebuild See Graphic: wc_gr001580 Teardown: 5.4.1 Remove drive belt. See Section Belt Replacement. 5.4.2 Remove 4 screws (a) from outside end of each universal joint (c). 5.4.3 Remove 2 bolts (d), washers (e) and nuts (f) from each bearing flange (g). 5.4.4 Remove the drive shaft and clutch as an assembly. 5.4.5 Remove 4 screws (b) from inside end of each universal joint (c).
Gearbox and Spider 6. CRT Repair Gearbox and Spider 6.1 Gearbox Basics See Graphic: wc_gr001579 Rotation of the gearboxes will differ depending on which side of the trowel the gearbox is located. Gearboxes located on the Right-hand side of the trowel rotate counterclockwise or left-hand rotation when viewed from the top. Gearboxes on the Left-hand side of the trowel rotate clockwise or right-hand rotation. The blade rotors rotate IN under the operator.
CRT Repair 6.2 Gearbox and Spider Gearbox Removal and Installation See Graphic: wc_gr001582 6.2.1 Place trowel on a flat, level surface large enough for the trowel and capable of supporting the weight of the trowel. To remove right side gearbox: 6.2.2 Drain water tank. Remove 2 bolts located under tank. 6.2.3 Remove water line from tank by loosening clamp and pulling off tube. Remove tank. To remove left side gearbox: 6.2.4 Close fuel valve. Remove bolts located under tank. 6.2.
Gearbox and Spider CRT Repair To install right side gearbox: 6.2.16 Replace water tank. Attach tube and tighten clamp. 6.2.17 Install 2 bolts located under tank. Fill water tank. To install left side gearbox: 6.2.18 Slide hose into fitting and tighten clamp. 6.2.19 Install bolts located under tank. Open fuel valve. q t u r, s u q c t a r, s a c wc_gr001582 wc_tx000095gb.
CRT Repair 6.3 Gearbox and Spider Spider Removal and Installation See Graphic: wc_gr001583, wc_gr001580 Removal: 6.3.1 Remove gearbox. See Section Gearbox Removal and Installation. 6.3.2 Loosen blade arms. For 36" models: • Remove grease fittings (aa) from spider. For 48" models: • 6.3.3 Remove stabilizer ring shoulder bolts (v) from arm ends and lift ring (y) off. Remove blades by removing mounting bolts (x) from arms. CAUTION: Blades may have sharp edges. 6.3.
Gearbox and Spider CRT Repair 6.3.15 Replace shoulder bolts (w) into lifting ring. Do not tighten if links are in need of adjustment. See Section Lift Ring Disassembly and Assembly. 6.3.16 Install blades using bolts (x) through arms. 6.3.17 Install spider onto gearbox. 6.3.18 Attach gearbox. See Section Gearbox Removal and Installation. wc_tx000095gb.
CRT Repair wc_tx000095gb.
Gearbox and Spider 6.4 CRT Repair Lift Ring Disassembly and Assembly See Graphic: wc_gr001583, wc_gr002447 Disassembly: 6.4.1 Remove gearbox. See Section Gearbox Removal and Installation. 6.4.2 Remove spider. See Section Spider Removal and Installation. 6.4.3 Lift ring assembly (ii) from spider. 6.4.4 Clamp assembly securely in vise and remove the lift cap (mm) by unthreading. 6.4.5 Remove seal ring (nn) and bearing holder (oo). Press bearing (pp) from bearing holder. Assembly: 6.4.
CRT Repair Gearbox and Spider 6.4.22 Using a combination square, place the end of the blade on the flat surface (2). 6.4.23 With the combination square’s blade against the front (raised) edge of the trowel blade, move the sliding portion down to the top of the trowel blade and lock it in place. 6.4.24 Check each blade against this measurement. 6.4.25 If adjustment is needed, remove shoulder bolt (w) and turn link (qq) in to increase or out to decrease blade angle.
Gearbox and Spider 6.5 CRT Repair Gearbox Disassembly See Graphic: wc_gr001584 6.5.1 Remove gearbox. See Section Gearbox Removal and Installation. 6.5.2 Remove spider assembly. See Section Spider Removal and Installation. 6.5.3 Remove the drain plug (a) and allow the oil to drain out. It may be necessary to remove the oil fill plug (cc) to facilitate draining. Open or remove pressure relief valve (b) if needed.
CRT Repair wc_tx000095gb.
Gearbox and Spider 6.6 CRT Repair Gearbox Assembly See Graphic: wc_gr001584 6.6.1 Pack area between the 2 seals (bb) with grease and press into bottom of gearbox, lip side facing inward. 6.6.2 Reassemble the input and output shafts. 6.6.3 Oil input shaft bearings (x) and loosely insert input shaft (r) into gearbox housing. 6.6.4 Pack upper bearing (u) with grease on output shaft (s) and lightly oil lower bearing (w). Carefully install output shaft into housing. 6.6.
CRT Repair 7. Steering and Pitch Control Steering and Pitch Control 7.1 Removal and Installation of Manual Steering Yokes See Graphic: wc_gr001581, wc_gr001653 Removal: 7.1.1 Unplug wiring harness (a). Remove 4 bolts (b) holding steering levers (d) on the handle mounts (c). 7.1.2 Remove 4 screws from front grill panel. Unplug water pump and remove panel. 7.1.3 Remove bolts (d, e) and spacers (f) from bottom of each steering lever. 7.1.4 Remove bolt (g) and nut (h) from each pivot bracket (i). 7.
Steering and Pitch Control CRT Repair 7.1.15 Center the steering handles. The left pivot bracket (v) must be in a horizontal position when the machine is at rest. This link attaches to the gearbox pivot and the left pivot bracket (v). To adjust, loosen the jam nuts on the left/right pivot link (u) and turn until the left pivot bracket (v) is horizontal. Torque the nuts to 75 Nm (55 ft.lbs.).
CRT Repair Steering and Pitch Control Honda (manual) Kohler (manual) wc_tx000096gb.
Steering and Pitch Control CRT Repair Vanguard (manual steering) wc_tx000096gb.
CRT Repair 7.2 Steering and Pitch Control Adjustment of Manual Steering See Graphic: wc_gr002337 Ref. Description Ref. Description a Tilts down 5° when steering handles are tilted towards seat e CRT 48: 13.97 cm (5 1/2") CRT 36: 12.70 cm (5") between center lines of tie-rods b 16.83 cm (6 5/8") 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.
Steering and Pitch Control 7.3 CRT Repair Pitch Control Removal and Installation See Graphic: wc_gr001585 Removal: 7.3.1 Remove water or fuel tank if necessary. See Section Gearbox Removal and Installation (steps 2-4). 7.3.2 Turn handle down (r) to remove tension on pitch cable (g). 7.3.3 Disconnect pitch cable (g) by removing locknut (t) located under the lift yoke (m). 7.3.4 Remove four screws (a) and nuts (b) from bottom of pitch control. Lift from machine. 7.3.
CRT Repair Steering and Pitch Control r n e f k g c d h i a b m l t wc_gr001585 wc_tx000096gb.
Steering and Pitch Control 7.4 CRT Repair Removal and Installation of Electric Steering Load Pins See Graphic: wc_gr002280 Removal: 7.4.1 Turn ignition switch to the OFF position. 7.4.2 Trowel should be on a flat surface with the blades pitched flat. 7.4.3 Flip seat assembly forward. Make sure seat lock engages. 7.4.4 For the rear actuator (left/right steering), remove the protective cover (a). 7.4.5 Disconnect the load pin wiring connector (b). 7.4.
CRT Repair wc_tx000096gb.
Steering and Pitch Control 7.5 CRT Repair Removal and Installation of Electric Steering Actuators See Graphic: wc_gr002280 Removal: 7.5.1 Turn ignition key to the “OFF” position. 7.5.2 Flip seat assembly forward. Make sure seat lock engages. 7.5.3 Disconnect actuator motor wiring harness (e) and load pin wiring connector (b). 7.5.4 Remove lower actuator mounting bolt or pin (f). 7.5.5 Remove the load pin retaining snap ring (c). 7.5.
CRT Repair 7.6 Steering and Pitch Control Removal and Installation of Electric Steering Joysticks See Graphic: wc_gr002341 Removal: 7.6.1 Disconnect negative battery cable. 7.6.2 Remove the 4 screws from the side of the housing and lift off. 7.6.3 Unplug the joystick from the wiring harness. 7.6.4 Remove the 4 nuts, screws and washers retaining the joystick in the housing. 7.6.5 Lower the joystick and backing plate from the housing. Installation: wc_tx000096gb.fm 7.6.
Steering and Pitch Control 7.7 CRT Repair Removal and Installation of Electric Steer Control Board Removal: 7.7.1 Make sure key switch is turned OFF. 7.7.2 Disconnect negative battery cable from battery. 7.7.3 Disconnect the gray and black control board connectors from the control board. 7.7.4 Remove the 4 nuts holding the wire cover on and remove the cover. 7.7.5 Check that the wires are labeled before removing them from the control board. 7.7.6 Remove the wires from the control board. 7.7.
CRT Repair Steering and Pitch Control Notes: wc_tx000096gb.
Steering and Pitch Control 7.8 CRT Repair Electric Steer Error Code Diagnostics and Troubleshooting See Graphic: wc_gr002279 When an error code is displayed via the flashing red warning lamp the following steps should always be followed. wc_tx000096gb.fm 7.8.1 Turn ignition switch OFF. Turn ignition switch back ON and check the steering system functionality on all 3 circuits; right, side, and left. If error warning lamp is no longer flashing and the system is functional, no further action is required.
CRT Repair Steering and Pitch Control 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 wc_tx000096gb.fm Ref.
Steering and Pitch Control CRT Repair Failure to follow the steps in this guide can cause irreparable damage to the electronic components in the steering system! WARNING 7.9 Error Code 111 - Right Actuator Fault 7.9.1 Perform a visual inspection of the right actuator wire connections and associated wiring. Inspect the mechanical parts to make sure no hardware is loose and the jam nut is tight. If no faults are found proceed to next step. 7.9.2 Turn ignition switch ON.
CRT Repair Steering and Pitch Control Turn ignition switch ON. Move the left joystick forward/back while watching the right actuator for movement. The control system will go into “open loop” as at this time there is no load pin feedback and the green lamp should flash. The right actuator must move in and out with corresponding left joystick movements. Turn ignition switch OFF. Disconnect the M3 wiring harness from the M1 actuator motor and move the harness back to its original position.
Steering and Pitch Control CRT Repair 7.10 Error Code 121 - Side Actuator Fault 7.10.1 Perform a visual inspection of the side actuator wire connections and associated wiring. Inspect the mechanical parts to make sure no hardware is loose and the jam nut is tight. If no faults are found proceed to next step. 7.10.2 Turn ignition switch ON. Watch for movement of the side actuator when the right joystick is moved to full left and right positions.
CRT Repair Steering and Pitch Control Turn ignition switch ON. Move the right joystick forward/back watching the side actuator for movement. The control system will go into “open loop” as at this time there is no load pin feedback and the green lamp should flash. The side actuator must move in and out with corresponding right joystick movements. Turn ignition switch OFF. Disconnect the M1 wiring harness from the M2 actuator motor and move the harness back to its original position.
Steering and Pitch Control CRT Repair 7.11 Error Code 131 - Left Actuator Fault 7.11.1 Perform a visual inspection of the left actuator wire connections and associated wiring. Inspect the mechanical parts to make sure no hardware is loose and the jam nut is tight. If no faults are found proceed to next step. 7.11.2 Turn ignition switch ON. Watch for movement of the left actuator when the left joystick is moved to full left and right positions.
CRT Repair Steering and Pitch Control Turn ignition switch ON. Move the right joystick forward/back while watching the left actuator for movement. The control system will go into “open loop” as at this time there is no load pin feedback and the green lamp should flash. The left actuator must move in and out with corresponding right joystick movements. Turn ignition switch OFF. Disconnect the M1 wiring harness from the M3 actuator motor and move the harness back to its original position.
Steering and Pitch Control CRT Repair 7.12 Error Code 211 - Right Load Pin Open Circuit 7.12.1 Check the right load pin L1 wire connections. Perform a visual inspection of the right load pin L1 and associated wiring. If no faults are found proceed to next step. 7.12.2 Use a digital volt/ohm meter to test for voltage at the black P2 control board connector. Turn ignition switch ON. Connect the black meter lead to a common ground.
CRT Repair Steering and Pitch Control 7.13.3 Turn ignition switch OFF. Remove the black P2 connector from the control board. Remove the orange locking plug from the front of the connector. Use a small screwdriver to release the locking tab and remove terminal #3 from the connector. Be sure to isolate the terminal from any metal surface. Install the orange locking plug and reinstall the connector. Turn ignition switch ON. Connect the red lead of the meter to the black wire from terminal #3.
Steering and Pitch Control CRT Repair 7.15 Error Code 222 - Side Load Pin Short Circuit 7.15.1 Check the side load pin L2 wire connections. Perform a visual inspection of the side load pin L2 and associated wiring. If no faults are found proceed to next step. 7.15.2 Use a digital volt/ohm meter to test for voltage at the black P2 control board connector. Turn the ignition switch to the ON position. Connect the black meter lead to a common ground.
CRT Repair Steering and Pitch Control 7.16 Error Code 231 - Left Load Pin Open Circuit wc_tx000096gb.fm 7.16.1 Check the left load pin L3 wire connections. Perform a visual inspection of the left load pin L3 and associated wiring. If no faults are found proceed to next step. 7.16.2 Use a digital volt/ohm meter to test for voltage at the black P2 control board connector. Turn ignition switch ON. Connect the black meter lead to a common ground.
Steering and Pitch Control CRT Repair 7.17 Error Code 232 - Left Load Pin Short Circuit 7.17.1 Check the left load pin L3 wire connections. Perform a visual inspection of the left load pin L3 and associated wiring. If no faults are found proceed to next step. 7.17.2 Use a digital volt/ohm meter to test for voltage at the black P2 control board connector. Turn ignition switch ON. Connect the black meter lead to a common ground. With the red meter lead, back probe the #7 terminal at the black P2 connector.
CRT Repair Steering and Pitch Control 7.18 Error Code 311 - Right Joystick Open Circuit wc_tx000096gb.fm 7.18.1 Check the right joystick wire connections. Perform a visual inspection of the right joystick and associated wiring. If no faults are found proceed to next step. 7.18.2 Use a digital volt/ohm meter to test for voltage at the gray P1 control board connector. Turn ignition switch ON. Connect the black meter lead to a common ground.
Steering and Pitch Control CRT Repair 7.19 Error Code 312 - Right Joystick Short Circuit 7.19.1 Check the right joystick wire connections. Perform a visual inspection of the right joystick and associated wiring. If no faults are found proceed to next step. 7.19.2 Use a digital volt/ohm meter to test for voltage at the gray P1 control board connector. Turn ignition switch ON. Connect the black meter lead to a common ground. With the red meter lead, back probe the #2 terminal at the gray P1 connector.
CRT Repair Steering and Pitch Control 7.20 Error Code 321 - Left Joystick Open Circuit wc_tx000096gb.fm 7.20.1 Check the left joystick wire connections. Perform a visual inspection of the left joystick and associated wiring. If no faults are found proceed to next step. 7.20.2 Use a digital volt/ohm meter to test for voltage at the gray P1 control board connector. Turn ignition switch ON. Connect the black meter lead to a common ground.
Steering and Pitch Control CRT Repair 7.21 Error Code 322 - Left Joystick Short Circuit 7.21.1 Check the left joystick wire connections. Perform a visual inspection of the left joystick and associated wiring. If no faults are found proceed to next step. 7.21.2 Use a digital volt/ohm meter to test for voltage at the gray P1 control board connector. Turn ignition switch ON. Connect the black meter lead to a common ground. With the red meter lead, back probe the #7 terminal at the gray P1 connector.
CRT Repair Steering and Pitch Control 7.22 Error Code 414 - Control Board Over Temperature 7.22.1 Shut down machine and allow control board to cool to ambient temperature. Inspect area surrounding control board and remove any accumulated debris. After machine has cooled attempt to run machine. If error code reappears replace the control board. 7.23 Error Code 415 - Low Battery Voltage 7.23.1 wc_tx000096gb.fm Inspect battery and all associated wiring. Remove all corrosion from battery terminals.
Engine 8. CRT Repair Engine 8.1 Engine Removal and Installation-Kohler or Honda Engine See Graphic: wc_gr002098 Removal: 8.1.1 Remove 4 nuts to remove cross brace. 8.1.2 Disconnect battery. 8.1.3 Close fuel valve on fuel tank. 8.1.4 Disconnect fuel line at fuel pump. 8.1.5 Unplug main engine harness (a). 8.1.6 Unplug single black wire from engine harness. 8.1.7 Unplug single white wire from engine harness. 8.1.8 Unplug single yellow to pink/purple/orange wires. 8.1.
CRT Repair wc_tx000097gb.fm Engine 8.1.28 Replace air cleaner base and attach with 3 bolts. Torque to 9.9 Nm (88 in. lbs.). Open choke (g). 8.1.29 Install air filter and cover. 8.1.30 Replace throttle cable. 8.1.31 Tighten up throttle mounting nuts. 8.1.32 Install cotter pin (f) from throttle cable connection. 8.1.33 Attach auxiliary power cable (e). 8.1.34 Attach battery cable (d). 8.1.35 Attach and tighten battery terminal nut (c) to starter. 8.1.
Engine CRT Repair b c a d e wc_gr002098 g f wc_tx000097gb.
CRT Repair 8.2 Engine Engine Removal and Installation-Vanguard Engine See Graphic: wc_gr002079 Removal: 8.2.1 Disconnect battery. 8.2.2 Lift trowel. Attach a slings or chains through the lifting bars 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. WARNING wc_tx000097gb.
Engine CRT Repair Installation: 8.2.22 Lift and slide the engine into the frame of the machine, using the lift brackets (m). 8.2.23 Apply Loctite 243 to the screws and install the 3 shockmount nuts into the front and side of the engine base. Torque to 25 Nm (18 ft.lbs.) 8.2.24 Install the universal joints and shims (if removed) to ends of drive shaft. Install the 4 bolts holding each inside universal joint to the shaft fitting. Torque to 17 Nm (12 ft.lbs.). 8.2.
CRT Repair Engine a m d b e g f i wc_tx000097gb.
Engine 8.3 wc_tx000097gb.
CRT Repair Engine Kohler Motor Ref. Description Ref.
Engine CRT Repair Kohler wc_tx000097gb.
CRT Repair Engine Kohler Motor Ref. Description Ref.
Engine 8.4 wc_tx000097gb.
CRT Repair Engine Honda Motor Ref. Description Ref.
Engine CRT Repair Honda wc_tx000097gb.
CRT Repair Engine Honda Motor Ref. Description Ref.
Engine 8.5 wc_tx000097gb.
CRT Repair Engine Vanguard Motor (manual steer) Ref. Description Ref.
Engine 8.6 wc_tx000097gb.
CRT Repair Engine Vanguard Motor (electric steer) Ref. Description Ref.
Engine CRT Repair Vanguard (electric steer) wc_tx000097gb.
CRT Repair Engine Vanguard Motor (electric steer) Ref. Description Ref.
Engine CRT Repair Notes: wc_tx000097gb.
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.
Threadlockers and Sealants TYPE ( ) = Europe Loctite Primer T Hernon Primer 10 Omnifit VC Activator COLOR USAGE Aerosol Spray Fast curing primer for threadlocking, retaining and sealing compounds. Must be used with stainless steel hardware. Recommended for use with gasket sealants. PART NO. SIZE 2006124 6 oz.
Torque Values Torque Values Metric Fasteners (DIN) TORQUE VALUES (Based on Bolt Size and Hardness) 8.8 10.9 WRENCH SIZE 12.9 Size ft.lb. Nm ft.lb. Nm ft.lb. 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.
Torque Values Inch Fasteners (SAE) Size ft.lb. Nm ft.lb. Nm ft.lb. Nm Inch Metric Inch Metric No.4 *6 0.7 *14 1.0 *12 1.4 1/4 5.5 3/32 - No.6 *12 1.4 *17 1.9 *21 2.4 5/16 8 7/64 - No.8 *22 2.5 *31 3.5 *42 4.7 11/32 9 9/64 - No.10 *32 3.6 *45 5.1 *60 6.8 3/8 - 5/32 - 1/4 6 8.
Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-354 02 - 0 · Fax: +49 - (0)89-354 02-390 Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : +1-(1)(262) 255-0500 · Fax: +1-(1)(262) 255-0550 · Tel. : (800) 770-0957 Wacker Asia Pacific Operations · Sunley Center, Unit 912, 9/F · 9 Wing Qin Street, Kwai Chung, N.T. · Hong Kong · Tel.
