WACKER Group CT 30 Series Operating instructions

www.wackergroup.com
Walk-Behind
Trowels
CT 30
CT 36
CT 48
REPAIR MANUAL
0112103 001
0600 en
0112103

TROWEL REPAIR FOREWORD
Operating / Parts Information
You must be familiar with the operation of this machine before you attempt to troubleshoot or make any repairs to it.
Basicoperating and maintenance procedures are described intheoperator’s/parts manual supplied with the machine.
The operator’s / parts manual should be kept with the machine. Use it to order replacement parts when needed. If this
manual becomes lost, please contact WACKER Corporation to order a replacement.
Damage caused by misuse or neglect of the unit should be brought to the attention of the operator, to prevent similar
occurrences from happening in the future.
This manual provides information and procedures to safely repair and maintain this WACKER model. For your own
safety and protection from injury, carefully read, understand and observe the safety instructions described in this
manual. THE INFORMATION CONTAINED IN THIS MANUAL WAS BASED ON MACHINES IN PRODUCTION AT
THE TIME OF PUBLICATION. WACKER CORPORATION RESERVES THE RIGHT TO CHANGE ANY PORTION
OF THIS INFORMATION WITHOUT NOTICE.
This manual covers machines with Serial Number or Item Number:
0007587, 0007589, 0007590, 0007591, 0007592, 0007594, 0007595, 0007596, 0007597, 0007598, 0007599, 0007601,
0007602, 0007603, 0007697, 0008001, 0008002, 0008003, 0008004, 0008005, 0008006, 0008007, 0008008, 0008011,
0008012, 0008013, 0008014, 0008015, 0008016, 0008019, 0008020, 0008026, 0008027, 0008028, 0008031, 0008032,
0008034, 0008036, 0008040, 0008041, 0008197, 0008198, 0008199, 0008225, 0008226
i

TROWEL REPAIR
PATENT PENDING
111545
FOREWORD
1022SD42
Serial Number
My machine’s numbers are:
RevisionItem Number
Model number
Rev. Serial Number
MENOMONEE FALLS, WI USA 53051
hpkWlbs
dB(A) Manuf. Yr.
Model
kg
MADE
IN USA
Item Number
88223
CT48AGT-ECT48AGT-E
CT48AGT-ECT48AGT-E
CT48AGT-E
00080320008032
00080320008032
0008032 101101
101101
101 0001010100010101
0001010100010101
00010101
®
Pro-Shift
Nameplate
A nameplate listing the Model Number and Serial Number OR the Model Number, Item Number, Revision, and Serial
Number is attached to each unit. Please record the information found on this plate so it will be available should the
nameplate become lost or damaged. When ordering parts or requesting service information, you will always be
asked to specify the model number and serial number OR the model number, item number, revision, and serial
number of the unit.
ii

Trowel
Repair Manual
1 Introduction
1.1 Safety Notes ................................................................................................ 1-2
1.2 Laws Pertaining to Spark Arresters .............................................................. 1-2
1.3 Operating Safety .......................................................................................... 1-3
1.4 Engine Safety............................................................................................... 1-3
1.5 Service Safety ............................................................................................. 1-4
1.6 Technical Data ............................................................................................. 1-5
1.7 Application ................................................................................................... 1-6
1.8 GeneralDescription ...................................................................................... 1-6
1.9 Periodic MaintenanceSchedule ................................................................... 1-6
1.10 Symbols ....................................................................................................... 1-6
2 Guide Handle
2.1 Throttle Control Lever Adjustment ................................................................ 2-1
2.2 Throttle CableReplacement ......................................................................... 2-1
2.3 Upper Handle - Twist Pitch Control - Exploded View ..................................... 2-2
2.4 Twist Pitch Control Cable Replacement ........................................................ 2-4
2.5 Upper Handle - Pro-Shift
®
- Exploded View ................................................... 2-6
2.6 Pro-Shift
®
Pitch Control Cable Replacement .................................................2-8
3 Clutch
3.1 Belt Replacement ......................................................................................... 3-1
3.2 Belt Drive - Exploded View ........................................................................... 3-2
3.3 ClutchReplacement ..................................................................................... 3-3
3.4 Clutch - Exploded View ................................................................................ 3-4
3.5 Clutch Overhaul............................................................................................ 3-5
4 Spider
4.1 Trowel Assembly - Exploded View ............................................................... 4-1
4.2 Spider........................................................................................................... 4-2
5 Drivetrain
5.1 Engine Removal - Exploded View ................................................................. 5-1
5.2 Engine .......................................................................................................... 5-2
5.3 Gearcase Removal - Exploded View............................................................. 5-3
5.4 Gearcase ..................................................................................................... 5-4
5.5 Gearbox - Exploded View ............................................................................. 5-6
5.6 GearcaseOverhaul ...................................................................................... 5-7
Troubleshooting
Table of Contents
1-1

1-2
1INTRODUCTION TROWEL REPAIR
1.1 SafetyNotes
This manual contains NOTES, CAUTIONS, and WARNINGS which must be followed to reduce the possibility of
improperservice, damagetothe equipment,orpersonalinjury.Read andfollowall NOTES,CAUTIONSand WARNINGS
included in instructions.
Note:
Containsadditional
information important to a procedure.
CAUTION:Provides information important to prevent
errors which could damage machine or components.
WARNING
Warns of conditions or practices which
could lead to personal injury or death!
1.2 Laws Pertaining to Spark Arresters
Notice: Some states require that in certain locations, spark arresters be used on internal combustion engines. A spark
arrester is a device designed to prevent the discharge of sparks or flames from the engine exhaust. It is often required
when operating equipment on forested land to reduce the risk of fires. Consult the engine distributor or local authorities
and make sure you comply with regulations regarding spark arresters.

TROWEL REPAIR INTRODUCTION 1
1-3
1.3 OperatingSafety
Familiarity and proper training are required for the safe operation of this equipment! Equipment operated improperly or
byuntrainedpersonnelcanbe dangerous! Read the operating instructions contained in both the operator'smanualand
the engine manual and familiarize yourself with the location and proper use of all controls.
DO NOT smoke while operating machine.
DO NOT smoke when refueling engine.
DO NOT refuel hot or running engine.
DO NOT refuel engine near open flame.
DO NOT spill fuel when refueling engine.
DO NOT run engine near open flames.
DO NOT run machine indoors or in an enclosed
area such as a deep trench unless adequate
ventilation, through such items as exhaust fans or
hoses, is provided. Exhaust gas from the engine
contains poisonous carbon monoxide gas; expo-
sure to carbon monoxide can cause loss of con-
sciousness and may lead to death.
ALWAYS refill fuel tank in well-ventilated area.
ALWAYS replace fuel tank cap after refueling.
NEVER allow anyone to operate this equipment
withoutproper training.Peopleoperating thisequip-
ment must be familiar with the risks and hazards
associated with it.
NEVER touch engine or muffler while the engine is
onor immediately afterithas beenturnedoff.These
areas get hot and may cause burns.
NEVERuseaccessoriesorattachmentswhichare
notrecommendedby WACKER. Damagetoequip-
ment and injury to the user may result.
NEVER operate machine with the belt guard miss-
ing. Exposed drive belt and pulleys create poten-
tially dangerous hazards that can cause serious
injuries.
NEVER leave machine running unattended.
1.4 EngineSafety
Internalcombustionengines present special hazardsduringoperationandfueling! Read and followwarninginstructions
in engine owner's manual and safety guidelines below. Failure to follow warnings and safety guidelines could result in
severe injury or death.
WARNING
ALWAYS be sure operator is familiar with proper
safety precautions and operation techniques be-
fore using machine.
ALWAYSwearprotectiveclothingwhen operating
equipment.Forinstance,gogglesorsafetyglasses
will protect eyes from damage caused by flying
debris.
ALWAYS close fuel valve on engines equipped
with one when machine is not being operated.
ALWAYS store equipment properly when it is not
being used. Equipment should be stored in a
clean, dry location out of the reach of children.
ALWAYSoperatemachinewith all safety devices
and guards in place and in working order.
WARNING

1-4
1INTRODUCTION TROWEL REPAIR
1.5 ServiceSafety
Poorlymaintainedequipment can becomeasafetyhazard! Inorderfortheequipment to operatesafelyandproperly over
a long period of time, periodic maintenance and occasional repairs are necessary.
WARNING
DO NOT attempt to clean or service machine
while it is running. Rotating parts can cause
severe injury.
DO NOT crank a flooded engine with the spark
plugremoved on gasoline-poweredengines.Fuel
trappedinthe cylinderwillsquirtout the sparkplug
opening.
DO NOT test for spark on gasoline-powered en-
gines, if engine is flooded or the smell of gasoline
is present. A stray spark could ignite fumes.
DO NOT use gasoline or other types of fuels or
flammable solvents to clean parts, especially in
enclosed areas. Fumes from fuels and solvents
can become explosive.
ALWAYS keep area around muffler free of debris
such as leaves, paper, cartons, etc. A hot muffler
could ignite them, starting a fire.
ALWAYS replace worn or damaged components
with spare parts designed and recommended by
WACKER.
ALWAYS disconnect spark plug on machines
equippedwith gasolineengines,before servicing,to
avoid accidental start-up.
ALWAYS keep machine clean and labels legible.
Replaceallmissing and hard-to-readlabels.Labels
provideimportant operatinginstructionsand warnof
dangersandhazards.

TROWEL REPAIR INTRODUCTION 1
1-5
1.6 TechnicalData
CT 36ADT/ CT 48ADT/
CT 30ADT CT 30AGT CT36ADP CT 36AGT CT 48ADP CT 48AGT
30 (762) 30 (762) 36 (914) 36 (914) 48 (1220) 48 (1220)
60–100 125–165 60–100 125–165 60–100 125–165
Trowel
4
Mobil SHC634
Approx. 45 (1330)
0–15
TrowelDiameter in. (mm)
Number of Blades
GearboxLubrication type
oz. (ml)
SpeedRange rpm
Pitch Range degrees°

1-6
1INTRODUCTION TROWEL REPAIR
1.7 Application
The CT series of trowels are modern, high production
machinesintendedforfloating andfinishingfreshlypoured
concrete slabs. The machine’s good balance, adjustable
handle, and easily accessible controls add to operator
comfort and productivity. An automatic stop switch, or a
combination of an automatic stop switch and an operator
present lever, provide added operator safety. Finishing
rates will depend on operator skill and job conditions.
1.8 GeneralDescription
For the CT product line of trowels, engine power is
transferred through a centrifugal clutch and V-belt to the
gearcase and down to the trowel blades. The four trowel
bladesare mountedonaspider assemblymountedonthe
gearcase output shaft. The spider assembly adjusts the
trowel angle by being raised by the yoke-trowel blade lift.
The trowels can be tilted from 0°- 15 °. The speed
of the trowels ranges from 60-165 rpm, depending on
the model.
1.9 PeriodicMaintenanceSchedule
The chart below lists basic trowel maintenance. Refer to engine manufacturer’s Operator’s Manual for information on
engine maintenance. A copy of the engine Operator’s Manual was supplied with the machine when it was shipped.
Daily After After Every two Every Every two
before each first weeks or month or years or
starting use 5 hours 50 hrs. 100 hrs. 750 hrs.
Check and tighten external hardware. ●
Grease trowel arms. ●
Check and adjust drive belt. ●●
Grease adjusting yoke. ●
Changegearcaseoil. ●
Inspect pitch cable. ●
Changetrowelgearcaselubricant. ●
1.10 Symbols
Symbols Used on Repair Pages
L1 Indicates a sealant or threadlocking compound to
be used when assembling part.
[L1] Refer to Sealant Chart at end of manual for
description of sealants.
T1 Indicates the correct torque value for
assemblingpart.
[T1] Refer to Torque Chart at end of manual for
standardtorquemeasurements.

TROWEL REPAIR GUIDE HANDLE 2
2-1
2.2 Throttle Cable Replacement
Machines are available with various styles of throttle
control. The replacement of this cable is basically the
same for all models.
Disassembly:
1. RemoveM6wing nut (d), filter cover, second M6 wing
nut, and filter.
2. Disconnect throttle cable (e) from throttle lever (f).
3. Pull throttle through cable raceway.
4. Disconnect cable clamp (h) from handle. Disconnect
throttle control lever (g) from handle.
5. Disconnect cable (e) from throttle control lever (g).
Assembly:
1. Reconnect cable (e) to throttle control lever (g).
2. Connect throttle control lever to handle.
3. Push throttle cable through cable raceway (j).
4. Connect throttle cable (e) to throttle lever (f).
5. Install cable clamp (h) to take up excess throttle cable.
6. Adjustthrottlecablesothatengineisinidlewhenthrottle
control lever is in the idle position. Tighten cable.
7. Reinstall air filter, wing nut, filter cover and second
wing nut (d).
1001RM01
d
e
f
1001RM02
h
g
1001RM17
ab
c
j
Thethrottlecontrolis used to vary the speedoftheengine
and to control the rpm of the trowel blades to meet
specific applications and job conditions.
The throttle control uses ratchet action to select and hold
the desired throttle position. If the throttle fails to hold its
selected position, check lever pressure adjustment and
ratchet action.
Adjustment:
1. Tighten hex nut (a) on top of throttle control lever (c)
to increase pressure on throttle control.
2. Lock adjustment in place by tightening jam nut (b).
2.1 Throttle Control Lever Adjustment

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

TROWEL REPAIR GUIDE HANDLE 2
2-3
1 Handle-grip 2
2 Handle-bicycle 1
3 Pin-roll style (incl. 1) 2
4 Knob-pitch control 2
5 Bearing-ball 1
6 Holder-handle bearing 1
7 Retaining ring-ext. 1
8 Screw M6x16 1
9 Shaft-pitch control 1
10 Nut 3/4-6 1
11 Pin-roll 1
12 Screw M6x10 1
13 Lever-throttle control 1
14 Clamp 1
15 Screw M5x25 1
16 Screw #8-32x1/4 2
17 Knob 1
Ref. Description Qty.
N2 - Lubricate threads before assembly.N1 - Fill bearing with grease before assembly.
Ref. Description Qty.
18 Screw 3/8-16x1-3/8 1
19 Casing-cable 1
20 Cable-throttle 1
21 Wiring harness 1
22 Cable-control, blade 1
23 Rod-handle adjustment 1
24 Cap-screw head 1
25 Nut-lock M5 1
26 Grommet 2
27 Washer B5.3 1
28 Screw M5x45 1
29 Nut BM5 1
30 Cover-switch box 1
31 Handle-switch 1
32 Retaining ring-ext. 1
33 Shaft-handle pivot 1
34 Handle-adjustable 1

2-4
2GUIDE HANDLE TROWEL REPAIR
fe
d
c
ba
1001RM03
h
g
m
a
j
k
1013SD53
2.4 Twist Pitch Control Cable Replacement
Disassembly:
1. Remove two retaining nuts (f) from the pitch control
cable (d).
2. Disengage cable from fork (e) and slide through
pulley (c).
3. Remove two M8 screws (a) holding handle to handle
base(b).Carefullypullhandleandcontrolcable away
from handle base.
4. Remove M6 screw (g) from handle. Remove
M6 screw (m) from underside of handle.
5. PullTwistControl assembly (j) andpitch control cable
(k) from handle.
6. Drive roll pin (h) from Twist Control assembly.
Remove cable.

TROWEL REPAIR GUIDE HANDLE 2
2-5
Assembly:
1. Place control cable terminal (k) into Twist Control
assembly (j). Drive roll pin (h) into assembly.
2. Lubricate threads on Twist Control assembly. Slide
cable down into handle. Turn twist control assembly
fully counterclockwise.
3. Place Twist Control assembly into handle, lining up
holesin handle.AttachM6screw(m)totheunderneath
of handle.
4. Apply Loctite 243 or equivalent to threads of M6 screw
(g). Attach to top of handle. Torque to 6 ft.lbs. (8 Nm).
5. Threadcablethroughhandlebase(b)andover pulley
(c). Slide handle into base.
6. Apply Loctite 243 or equivalent and attach two
M8 screws (a)to handle. Torque to 16 ft.lbs. (22 Nm).
7. Threadcontrolcablefork(e)andattachretainingnuts
(f). Adjust cable nuts until cable is snug and trowel
blades lay flat (0opitch).

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

TROWEL REPAIR GUIDE HANDLE 2
2-7
1 Handle-grip 2
2 Handle-bicycle style (incl. 1) 1
3 Handle- Pro-Shift® 1
4 Washer-retaining 2
5 Pin-dowel 1
6 Screw 3
7 Cover- Pro-Shift® 1
8 Washer 2
9 Spring-wave stack 2
10 Plate-serrated 4
11 Screw M6x12 2
12 Spring-torsion 1
13 Tube-spring mandrel 1
14 Screw M8x25 6
15 Rod-threaded, M12 1
16 Nut-lock, M12 2
17 Housing- Pro-Shift® 1
18 Handle-adjustable 1
19 Lever-throttle control 1
20 Clamp 2
21 Screw M5x25 2
Ref. Description Qty. Ref. Description Qty.
22 Knob 1
23 Screw 3/8-16x1-3/8 1
24 Casing-cable 1
25 Cable-throttle 1
26 Wiring harness w/lever 1
27 Cable-pitch, control 1
28 Screw #8-32x1/4 2
29 Rod-handle adjustment 1
30 Knob-pitch control 1
31 Pin-roll 1
32 Grommet 2
33 Washer 1
34 Screw 1
35 Nut 1
36 Cover-switch box 1
37 Handle-switch 1
38 Retaining ring-ext. 1
39 Shaft-handle pivot 1
40 Cap-screw head 1
41 Nut-lock M5 1

2-8
2GUIDE HANDLE TROWEL REPAIR
WARNING
1001RM04
d
k
fe
j
g
a
b
c
m
h
sr
q
p
on
n
1013SD53
2.6 Pro-Shift® Pitch Control Cable Replacement
Due to tension in torsional spring, the Pro-Shift
®
handle may snap back abruptly and strike
personnel working in the vicinity.
Disassembly:
1. Push Pro-Shift
®
handle (a) all the way forward. Re-
move two M6 screws (d) and cover (e) from
Pro-
Shift
®
assembly.
2. Remove two retaining nuts (s) from the pitch control
cable (q).
3. Disengage cable from fork (r) and slide through
pulley (p).
4. Pull the
Pro-Shift
®
handle all the way back.
5. Remove two M8 screws (n) holding handle to handle
base(o).Carefullypullhandleandcablecontrol away
from handle base.
6. Remove M6 screw (k) from handle. Pull Pro-Shift
®
assembly and pitch control cable from handle.
7. Remove threaded rod (h) from housing (j).
Note: On some models the threaded rod may be
replaced by a bolt.
8. Remove M8 screws (g). Pry out torsional spring (m)
and mandrel (f).
9. Using pliers, squeeze handle legs (a) together and
remove handle.
10. Slide dowel pin (b) to one side.
Note: On some models, the dowel pin may have a
retaining washer (c) .
11. Slide control cable off of dowel pin.

TROWEL REPAIR GUIDE HANDLE 2
2-9
1001RM14
1001RM15
1001RM16
t
u
v
wx
yzaabb
Assembly:
1. Place Pro-Shift
®
housing in a vise. Make sure that the
two washers (t), wave spring (u), and serrated plate
(v) are positioned properly over each pivot tube.
2. Slide control cable over dowel pin. Slide dowel pin
back into position through handle legs (x). If so
equipped, install retaining washer.
3. Using pliers, squeeze handle legs (x) together and
slip handle into place on the pivot tubes. Make sure
that the handle is seated properly.
4. Using C-clamps, evenly compress the wave springs
against the housing until the holes in the handle are
flush with the pivot tubes (w).
5. Slide torsional spring (z) over mandrel (y) and insert
assembly between pivot tubes.
6. Insert threaded rod (aa) and secure with nuts (bb).
On some machines this rod may be replaced with
a bolt.

2-10
2GUIDE HANDLE TROWEL REPAIR
7. Checkmovementofhandle. Handle should be able to
move with some resistance. Adjust nut as necessary.
8. Reinstall cover (b) over assembly using M6 screws
(a). Torque to 7 ft.lbs. (10 Nm).
9. Slide pitch control cable through handle and insert
Pro-Shift
®
assembly.
10. Apply Loctite 243 or equivalent to M6 screw (c)
and reinstall in handle. Torque to 6 ft.lbs. (8 Nm).
11. Push Pro-Shift
®
handle fully forward.Thread cable
through handle base (d) and over pulley (f). Slide
handle into base.
12. Apply Loctite 243 or equivalent and attach two M8
screws (e) to handle. Torque to 16 ft.lbs. (22 Nm).
13. Install hitch pin into handle.
14. Thread control cable (g) through fork (h). Adjust
retaining nuts (j) until cable is snug and trowel
blades lay flat (0°pitch).
1001RM04
a
c
b
jh
g
f
de
e
1013SD53