Wacker Neuson CT 36 Operating instructions

www.wackergroup.com
Walk-Behind
Trowels
CT 36
CT 48
REPAIR MANUAL
0163091en 003
1007
0163091EN

CT Repair Foreword
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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 / 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 the above Wacker model(s). For your own safety and
protection from injury, carefully read, understand, and observe all
instructions described in this manual. THE INFORMATION
CONTAINED IN THIS MANUAL IS BASED ON MACHINES
MANUFACTURED UP TO THE TIME OF PUBLICATION. WACKER
CORPORATION RESERVES THE RIGHT TO CHANGE ANY
PORTION OF THIS INFORMATION WITHOUT NOTICE.
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.
This manual covers machines with Item Number:
0009438, 0009439, 0009442, 0009443, 0009444, 0009447, 0009449,
0009450, 0009452, 0009453, 0620106
WARNING

CT Repair Foreword
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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.
Keep this manual or a copy of it with the machine. If you lose this
manual or need an additional copy, please contact Wacker
Corporation. This machine is built with user safety in mind; however,
it can present hazards if improperly operated and serviced. Follow
operating instructions carefully! If you have questions about operating
or servicing this equipment, please contact Wacker Corporation.
The information contained in this manual was based on machines in
production at the time of publication. Wacker Corporation reserves the
right to change any portion of this information without notice.
All rights, especially copying and distribution rights, are reserved.
Copyright 2007 by Wacker Corporation.
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express written permission from Wacker Corporation.
Any type of reproduction or distribution not authorized by Wacker
Corporation represents an infringement of valid copyrights and will be
prosecuted. We expressly reserve the right to make technical
modifications, even without due notice, which aim at improving our
machines or their safety standards.

CT Repair Table of Contents
5
1. Safety Information 8
1.1 Laws Pertaining to Spark Arrestors ...................................................... 8
1.2 Operating Safety .................................................................................. 9
1.3 Operator Safety while using Internal Combustion Engines ................ 10
1.4 Service Safety .................................................................................... 11
1.5 Label Locations .................................................................................. 12
1.6 Safety and Information Labels ............................................................ 13
2. Technical Data 18
2.1 Dimensions and Weight ..................................................................... 18
2.2 Engine ................................................................................................ 20
2.3 Trowel ................................................................................................. 24
2.4 Sound and Vibration Data .................................................................. 25
3. Operation 26
3.1 Application .......................................................................................... 26
3.2 New Machine Set-up .......................................................................... 26
3.3 Recommended Fuel ........................................................................... 26
3.4 Installing Blades ................................................................................. 27
3.5 Installing and Adjusting Handles ........................................................ 28
3.6 Controls .............................................................................................. 30
3.7 Stop Button ......................................................................................... 31
3.8 Before Starting ................................................................................... 31
3.9 To Start - Honda ................................................................................. 32
3.10 To Stop - Honda ................................................................................. 33
3.11 To Start - Wacker ............................................................................... 34
3.12 To Stop - Wacker ............................................................................... 35
3.13 Engine Control Module ....................................................................... 36
3.14 Operation ............................................................................................ 36
3.15 Braking System .................................................................................. 38
3.16 Pitch Adjustment ................................................................................ 39

Table of Contents CT Repair
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4. Maintenance 40
4.1 Periodic Maintenance Schedule - Honda ............................................40
4.2 Periodic Maintenance Schedule - Wacker ..........................................41
4.3 Engine Oil - Honda ..............................................................................42
4.4 Engine Oil - Wacker ............................................................................43
4.5 Air Cleaner - Honda .............................................................................44
4.6 Air Cleaner - Wacker ...........................................................................45
4.7 Spark Plug ...........................................................................................46
4.8 Cleaning Sediment Cup - Honda .........................................................47
4.9 Cleaning Fuel Strainer - Wacker .........................................................47
4.10 Adjusting Idle Speed - Honda ..............................................................48
4.11 Carburetor Adjustment - Honda ..........................................................49
4.12 Belt Replacement ................................................................................50
4.13 Trowel Lubrication ...............................................................................51
4.14 Optional Weights .................................................................................51
4.15 Lifting ...................................................................................................52
4.16 Storage ................................................................................................54
4.17 Troubleshooting ...................................................................................55
5. Guide Handle 56
5.1 Replacing the Throttle Cable ...............................................................56
5.2 Adjusting the Throttle Lever ................................................................58
5.3 Upper Handle/Twist Pitch Control—Exploded View ............................60
5.4 Upper Handle/Twist Pitch Control—Components ...............................61
5.5 Replacing the Upper Handle ...............................................................62
5.6 Replacing the Twist Pitch Control Cable .............................................64
5.7 Replacing the Lower Handle ...............................................................66
5.8 Replacing the Stop Switch ..................................................................67
6. Clutch 69
6.1 Replacing the Drive Belt ......................................................................69
6.2 Drive Belt—Standard Clutch ...............................................................70
6.3 Drive Belt—Variable Speed Clutch .....................................................71
6.4 Replacing the Standard Clutch ............................................................72
6.5 Standard Clutch—Exploded View .......................................................73
6.6 Standard Clutch Overhaul ...................................................................74
6.7 Replacing the Variable Speed Clutch ..................................................76

CT Repair Table of Contents
7
7. Spider 78
7.1 Spider Assembly—Exploded View ..................................................... 78
7.2 Spider Assembly—Components ........................................................ 79
7.3 Replacing the Blades ......................................................................... 80
7.4 Replacing the Arms ............................................................................ 82
7.5 Balancing the Blade Pitch .................................................................. 84
7.6 Removing the Spider .......................................................................... 86
7.7 Installing the Spider ............................................................................ 88
7.8 Rebuilding the Lift Ring Assembly ...................................................... 90
8. Drivetrain 92
8.1 Drivetrain—Exploded View ................................................................. 92
8.2 Drivetrain—Components .................................................................... 93
8.3 Engine Removal ................................................................................. 94
8.4 Engine Installation .............................................................................. 96
8.5 Engine Wiring ..................................................................................... 98
8.6 Engine Wiring Components ................................................................ 99
8.7 Wiring Diagrams ............................................................................... 100
8.8 Engine Wiring Components .............................................................. 101
8.9 Replacing the Gearbox ..................................................................... 102
8.10 Gearbox—Exploded View ................................................................ 104
8.11 Gearbox—Components .................................................................... 105
8.12 Gearbox Disassembly ...................................................................... 106
8.13 Gearbox Assembly ........................................................................... 110

Safety Information CT 36 / CT 48
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1. Safety Information
This manual contains DANGER, WARNING, CAUTION, NOTICE 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.
DANGER indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTICE:Used without the safety alert symbol, NOTICE indicates a
hazardous situation which, if not avoided, could result in property
damage.
Note: Contains additional information important to a procedure.
1.1 Laws Pertaining to Spark Arrestors
Notice: State Health Safety Codes and Public Resources Codes
specify that in certain locations spark arresters be used on internal
combustion engines that use hydrocarbon fuels. A spark arrester is a
device designed to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified and rated by
the United States Forest Service for this purpose.
In order to comply with local laws regarding spark arresters, consult
the engine distributor or the local Health and Safety Administrator.
DANGER
WARNING
CAUTION

CT 36 / CT 48 Safety Information
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1.2 Operating Safety
Familiarity and proper training are required for the safe operation of
machine. Machines 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. Inexperienced operators should
receive instruction from someone familiar with the machine before
being allowed to operate it.
1.2.1 NEVER allow anyone to operate this equipment without proper
training. People operating this equipment must be familiar with the
risks and hazards associated with it.
1.2.2 NEVER touch the engine or muffler while the engine is on or
immediately after it has been turned off. These areas get hot and may
cause burns.
1.2.3 NEVER use accessories or attachments that are not recommended by
Wacker. Damage to equipment and injury to the user may result.
1.2.4 NEVER leave machine running unattended.
1.2.5 NEVER operate the machine with the beltguard missing. Exposed
drive belt and pulleys create potentially dangerous hazards that can
cause serious injuries.
1.2.6 NEVER operate this machine in applications for which it is not
intended.
1.2.7 NEVER use the trowel around pop-ups in the concrete that are lower
than the lowest ring on the ring guard.
1.2.8 NEVER lift the machine solely by the handle. The component may fail,
causing the machine to fall, possibly injuring bystanders.
1.2.9 ALWAYS wear protective clothing appropriate to the job site when
operating equipment.
1.2.10 ALWAYS wear hearing and eye protection when operating this
machine.
1.2.11 ALWAYS remain aware of moving parts and keep hands, feet, and
loose clothing away from the moving parts of the machine.
1.2.12 ALWAYS read, understand, and follow procedures in the Operator’s
Manual before attempting to operate the equipment.
1.2.13 ALWAYS store the equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the reach of
children.
1.2.14 ALWAYS close fuel valve on engines equipped with one when
machine is not being operated.
WARNING

Safety Information CT 36 / CT 48
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1.2.15 ALWAYS operate machine with all safety devices and guards in place
and in working order. DO NOT modify or defeat safety devices. DO
NOT operate machine if any safety devices or guards are missing or
inoperative.
1.2.16 ALWAYS be sure operator is familiar with proper safety precautions
and operation techniques before using machine.
1.2.17 ALWAYS test the function of the engine control module before
operating the trowel. DO NOT operate the trowel if the engine control
module is not functioning properly.
1.3 Operator Safety while using Internal Combustion Engines
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.
1.3.1 DO NOT run the 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; exposure to carbon
monoxide can cause loss of consciousness and may lead to death.
1.3.2 DO NOT smoke while operating the machine.
1.3.3 DO NOT smoke when refueling the engine.
1.3.4 DO NOT refuel a hot or running engine.
1.3.5 DO NOT refuel the engine near an open flame.
1.3.6 DO NOT spill fuel when refueling the engine.
1.3.7 DO NOT run the engine near open flames.
1.3.8 ALWAYS refill the fuel tank in a well-ventilated area.
1.3.9 ALWAYS replace the fuel tank cap after refueling.
DANGER

CT 36 / CT 48 Safety Information
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1.4 Service Safety
Poorly maintained machines can become a safety hazard! In order for
the machine to operate safely and properly over a long period of time,
periodic maintenance and occasional repairs are necessary.
1.4.1 DO NOT attempt to clean or service the machine while it is running.
Rotating parts can cause severe injury.
1.4.2 DO NOT crank a flooded engine with the spark plug removed on
gasoline-powered engines. Fuel trapped in the cylinder will squirt out
the spark plug opening.
1.4.3 DO NOT test for spark on gasoline-powered engines if the engine is
flooded or the smell of gasoline is present. A stray spark could ignite
the fumes.
1.4.4 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.
1.4.5 DO NOT remove blades while the machine is hanging overhead.
1.4.6 ALWAYS support the machine securely before changing blades.
1.4.7 ALWAYS keep the area around the muffler free of debris such as
leaves, paper, cartons, etc. A hot muffler could ignite the debris and
start a fire.
1.4.8 ALWAYS replace worn or damaged components with spare parts
designed and recommended by Wacker Corporation.
1.4.9 ALWAYS disconnect the spark plug on machines equipped with
gasoline engines, before servicing, to avoid accidental start-up.
1.4.10 ALWAYS keep the machine clean and labels legible. Replace all
missing and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.
1.4.11 ALWAYS handle blades carefully. The blades can develop sharp
edges which can cause serious cuts.
WARNING

Safety Information CT 36 / CT 48
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1.5 Label Locations

CT 36 / CT 48 Safety Information
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1.6 Safety and Information Labels
Wacker machines use international pictorial labels where needed.
These labels are described below:
Label Meaning
DANGER!
Engines emit carbon monoxide; operate only
in well-ventilated area. Read the Operator’s
Manual.
No sparks, flames, or burning objects near the
machine. Shut off the engine before refueling.
WARNING!
Hot surface!
WARNING!
Hand injury if caught in moving belt.
Always replace beltguard.
WARNING!
Always wear hearing and eye protection when
operating this machine.
WARNING!
Cutting hazard. Always replace blade guard!

Safety Information CT 36 / CT 48
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WARNING!
Remove pan from trowel before lifting machine
overhead. Pans can fall and cause death or
serious injury if a person is hit. (Located on top
side of float pan.)
Variable speed throttle
CAUTION!
Read and understand the supplied Operator’s
Manuals before operating this machine. Fail-
ure to do so increases the risk of injury to your-
self or others.
CAUTION!
Lifting point.
Engine stop button:
Press to stop engine.
Label Meaning
1 1 8 6 8 8
R e m o v e p a n f r o m t r o w e l b e f o r e l i f t i n g m a c h i n e
o v e r h e a d .
P a n s c a n f a l l a n d c a u s e d e a t h o r s e r i o u s i n j u r y i f
a p e r s o n i s h i t .
G l e i t s c h e i b e v o m e t o n g l ä t t e r e n t f e r n e n b e v o r
d a s G e r ä t u b e r K o p f h ö h e g e h o b e n w i r d .
G l e i t s c h e i b e k a n n f a l l e n u n d s c h w e r e V e r l e t z u n g
o d e r T o d v e r u r s a c h e n w e n n P e r s o n a l g e t r o f f e n w i r d .
Q u i t e e l d i s c o d e f l o t a c i ó n a n t e s d e l e v a n t a r l a
m á q u i n a a l i s a d o r a d e h o r m i g ó n .
L o s d i s c o s p o d r í a n c a e r y m a t a r o l a s t i m a r
s e r i a m e n t e a u n a p e r s o n a q u e s e e n c u e n t r e c e r c a .
A v a n t d e l e v e r l  a p p a r e i l a u - d e s s u s d e v o t r e t ê t e ,
ô t e r l e d i s q u e d e t a l o c h a g e d e l a t r u e l l e .
L e d i s q u e d e t a l o c h a g e p e u t t o m b e r e t e n t r a î n e r
d e g r a v e s b l e s s u r e s o u m ê m e l a m o r t .

CT 36 / CT 48 Safety Information
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A nameplate listing the model number, item
number, revision number, and serial number is
attached to each unit. Please record the infor-
mation found on this plate so it will be available
should the nameplate become lost or dam-
aged. When ordering parts or requesting ser-
vice information, you will always be asked to
specify the model number, item number, revi-
sion number, and serial number of the unit.
Use only Glygoyle 460 gear oil in gearbox.
This machine may be covered by one or more
patents.
Label Meaning

Safety Information CT 36 / CT 48
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Label Meaning
Open the fuel flow valve.
Close the choke.
Turn engine key switch to “ON” position.
Place throttle in the IDLE position.
Pull the rewind starter.
Open the choke.

CT 36 / CT 48 Safety Information
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Press the stop button.
Turn engine key switch to “OFF” position.
Close the fuel flow valve.
Label Meaning

Technical Data CT 36 / CT 48
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2. Technical Data
2.1 Dimensions and Weight
Guide
*Standard models feature Wacker engine.
Description Ref. Description Ref.
Honda engine* A Variable Speed V
Engine Horse Power 4, 5, 6, 8, 9, 11, 13
Handle Type Item No. L
mm(in.)
Pitch
Type
Weight
kg (lbs.)
Solid 0159659 1740 (68.5) Twist 10 (21)
Folding 0159660 1740 (68.5) Twist 12 (26.5)
Adjustable/Folding 0164617 1740 (68.5) Twist 13 (28)
Adjustable 0164535 1740 (68.5) Twist 11 (24.5)
Adjustable/Folding 0159661 1740 (68.5) Pro-Shift® 15 (32.5)
Adjustable 0159662 1740 (68.5) Pro-Shift® 13 (29)

CT 36 / CT 48 Technical Data
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without handle with handle
Model Item No.
LxWxH
mm
(in.)
LxWxH
mm
(in.)
without
weight kit
kg (lbs.)
with
weight kit
kg (lbs.)
CT 36-5A 0009438
0620106
915x915x607
(36x36x24)
2005x915x1040
(79x36x41) 85 (183) 91 (201)
CT 36-6 0009443 915x915x607
(36x36x24)
2005x915x1040
(79x36x41) 85 (183) 91 (201)
CT 36-8A 0009439 915x915x686
(36x36x27)
2005x915x1040
(79x36x41) 94 (208) 103 (226)
CT 36-8A-V 0009442 915x915x686
(36x36x27)
2005x915x1040
(79x36x41) 94 (208) 103 (226)
CT 36-9 0009444 915x915x686
(36x36x27)
2005x915x1040
(79x36x41) 90 (199) 98 (217)
CT 36-9-V 0009447 915x915x686
(36x36x27)
2005x915x1040
(79x36x41) 90 (199) 98 (217)
CT 48-8A 0009449 1220x1220x686
(48x48x27)
2160x1220x1040
(85x48x41) 105 (234) 114 (252)
CT 48-9 0009453 1220x1220x686
(48x48x27)
2160x1220x1040
(85x48x41) 105 (234) 114 (252)
CT 48-11A 0009450 1220x1220x712
(48x48x28)
2160x1220x1040
(85x48x41) 113 (250) 122 (268)
CT 48-13A-V 0009452 1220x1220x712
(48x48x28)
2160x1220x1040
(85x48x41) 121 (268) 130 (286)

Technical Data CT 36 / CT 48
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2.2 Engine
Item No. CT 36-5A
0009438, 0620106
CT 36-6
0009443
Engine
Engine Make Honda Wacker
Engine Model GX 160 K1 QX2 WM170
Rated Power kW (Hp) 4.3 (5.7) @ 3800rpm 4.2 (5.6) @ 3800 rpm
Spark Plug NGK BPR 6ES NGK BR6HS
Champion RL86C
Electrode Gap mm (in.) 0.7 – 0.8 (0.028 – 0.031) 0.6–0.7 (0.024–0.028)
Engine Speed - full load rpm 3800 ± 100
Engine Speed - idle rpm 1450 ± 100 1400 ± 100
Clutch engagement rpm 1800
Valve Clearance (cold)
intake:
exhaust:
mm (in.) 0.15 (0.006)
0.20 (0.008)
0.07–0.13 (0.0028–0.0051)
0.17–0.23 (0.0067–0.0091
Air Cleaner type Dual element
Engine Lubrication oil grade SAE 10W30 SG or SF SAE 10W30
SE or higher
Engine Oil Capacity l (oz.) 0.6 (20)
Fuel type Regular unleaded gasoline
Fuel Tank Capacity l (qts.) 3.6 (3.8)
Fuel Consumption l (qts.)
/hr 1.8 (1.9) 1.52 (1.6)
Running time hr. 22.4