Wacker Neuson CRT 48-31V Repair manual

www.wackergroup.com
0163146en
001
0307
Ride-On Trowels
CRT 36-24A
CRT 48-31V
CRT 48-31V-ES
REPAIR MANUAL
0
1
6
3
1
4
6
E
N
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. Use the separate Parts Book supplied with the machine to order
replacement parts. If you are missing either of the documents, 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.
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i
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.
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
violators 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.
Laws Pertaining to Spark Arresters
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.
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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) .......................................... 10
Label Locations—CRT 48 (electric steer) ........................................ 12
Safety and Operating Labels .............................................................. 14
20
Engine—CRT 36 ................................................................................ 20
Trowel—CRT 36 ................................................................................. 21
Sound and Vibration Specifications—CRT 36 .................................... 22
Engine—CRT 48 (manual steer) ........................................................ 23
Trowel—CRT 48 (manual steer) ........................................................ 24
Sound and Vibration Specifications—CRT 48 (manual steer) ........... 25
Engine—CRT 48 (electric steer) ........................................................ 26
Trowel—CRT 48 (electric steer) ......................................................... 27
Sound and Vibration Specifications—CRT 48 (electric steer) ............ 28
Operation
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4.
4
Technical Data
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3.
Table of Contents
29
Description ......................................................................................... 29
Information Regarding Operation ....................................................... 29
Features and Controls—CRT 36/48 Manual Steer ............................ 30
Features and Controls—CRT 48 Electric Steer ................................. 31
Before Starting ................................................................................... 32
Starting ............................................................................................... 32
Stopping ............................................................................................. 32
Maintenance
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
34
Periodic Maintenance Schedule—CRT 36 ......................................... 34
Periodic Maintenance Schedule—CRT 48 ......................................... 35
Trowel Gearboxes .............................................................................. 36
Lubrication .......................................................................................... 37
Switching Blade Positions .................................................................. 38
Mounting Float Pans .......................................................................... 39
Transporting Trowels .......................................................................... 40
Spark Plug—CRT 36 .......................................................................... 41
Spark Plug—CRT 48 .......................................................................... 41
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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 ............................................................................44
Engine Oil—CRT 48 ............................................................................45
Basic Troubleshooting .........................................................................46
Drive Train
5.1
5.2
6.
CRT Repair
52
Gearbox Basics ...................................................................................52
Gearbox Removal and Installation ......................................................54
Spider Removal and Installation ..........................................................58
Lift Ring Disassembly and Assembly ..................................................62
Adjusting Blade Angle .........................................................................64
Gearbox Disassembly .........................................................................66
Gearbox Assembly ..............................................................................68
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
70
Pitch Control Removal and Installation ...............................................70
Removing and Installing the Manual Steering System—CRT 36 ........72
Removing and Installing the Manual Steering System—CRT 48 ........74
Adjusting Control Arm Pitch (forward or backward) ............................76
Adjusting the Right-hand Control Arm (right or left) ............................76
Adjusting Steering Arm Responsiveness ............................................78
Centering the Steering Arms ...............................................................80
Adjustment Values for the Manual Steering System ...........................81
Electric Steering System Background .................................................82
“Limp Home” Mode ..............................................................................84
Error Codes .........................................................................................84
Error Code 111—Right Actuator Fault ................................................86
Error Code 121—Side Actuator Fault ..................................................88
Error Code 131—Left Actuator Fault ...................................................90
Error Code 211—Right Load Pin Open Circuit ....................................92
Error Code 212—Right Load Pin Short Circuit ....................................94
Error Code 221—Side Load Pin Open Circuit .....................................97
Error Code 222—Side Load Pin Short Circuit .....................................99
Error Code 231—Left Load Pin Open Circuit ....................................102
Error Code 232—Left Load Pin Short Circuit ....................................104
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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 ........................... 120
Error Code 414—Control Board Overtemperature ........................... 121
Removal and Installation of Actuator Load Pins ............................... 122
Removal and Installation of Actuators .............................................. 124
Removal and Installation of Joysticks .............................................. 126
Removal and Installation of Electric Steer Control Board ................ 128
Engine Troubleshooting and Replacement
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
8.13
8.14
8.15
8.16
8.17
8.18
8.19
8.20
130
Vanguard Engine Does Not Crank—Flowchart 1A .......................... 130
Checking 70A Fuse .......................................................................... 131
Checking Voltage to Starter Motor ................................................... 132
Checking Ignition Switch .................................................................. 133
Vanguard Engine Cranks but does not Start—Flowchart 2A ........... 134
Checking Fuel Pump ........................................................................ 135
Checking 15A Fuse .......................................................................... 136
Checking Operator Presence Relay ................................................. 137
Checking Wiring to and Function of Throttle Switch ......................... 138
Vanguard Engine Cranks but does not Start—Flowchart 2B ........... 140
Checking Fuel Relay ........................................................................ 141
Checking Ignition Module ................................................................. 142
Honda Engine Does Not Crank—Flowchart 3A ............................... 143
Removing the Honda Engine ........................................................... 144
Installing the Honda Engine ............................................................. 146
Removing the Vanguard Engine ...................................................... 148
Installing the Vanguard Engine ........................................................ 150
Wiring Schematic—Honda ............................................................... 152
Wiring Schematic-Vanguard Engine (manual steer) ........................ 154
Wiring Schematic-Vanguard Engine (electric steer) ......................... 156
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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.
DANGER indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
DANGER
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
WARNING
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
CAUTION
CAUTION: Used without the safety alert symbol, CAUTION indicates
a potentially hazardous situation which, if not avoided, may result in
property damage.
Note: Contains additional information important to a procedure.
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4
CRT Repair
1.1
Operating Safety
WARNING
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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. Inexperienced operators should
receive instruction from someone familiar with the equipment before
being allowed to operate the machine.
1.1.1
NEVER operate this machine in applications for which it is not
intended.
1.1.2
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.
1.1.3
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.
1.1.4
NEVER use accessories or attachments that are not recommended by
Wacker. Damage to equipment and injury to the user may result.
1.1.5
NEVER operate the machine with the beltguard missing. Exposed
drive belt and pulleys create potentially dangerous hazards that can
cause serious injuries.
1.1.6
NEVER leave machine running unattended.
1.1.7
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.
1.1.8
ALWAYS remain aware of moving parts and keep hands, feet, and
loose clothing away from the moving parts of the equipment.
1.1.9
ALWAYS wear protective clothing appropriate to the job site when
operating equipment.
1.1.10
ALWAYS read, understand, and follow procedures in the Operator’s
Manual before attempting to operate the equipment.
1.1.11
ALWAYS be sure operator is familiar with proper safety precautions
and operation techniques before using machine.
1.1.12
ALWAYS close fuel valve on engines equipped with one when
machine is not being operated.
1.1.13
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.
1.1.14
ALWAYS operate the machine with all safety devices and guards in
place and in working order.
5
Safety Information
1.2
Operator Safety while using Internal Combustion Engines
DANGER
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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.
1.2.1
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.
1.2.2
DO NOT smoke while operating the machine.
1.2.3
DO NOT smoke when refueling the engine.
1.2.4
DO NOT refuel a hot or running engine.
1.2.5
DO NOT refuel the engine near an open flame.
1.2.6
DO NOT spill fuel when refueling the engine.
1.2.7
DO NOT run the engine near open flames.
1.2.8
ALWAYS refill the fuel tank in a well-ventilated area.
1.2.9
ALWAYS replace the fuel tank cap after refueling.
1.2.10
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.
6
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
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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. Fuel trapped in the cylinder will squirt out
the spark plug opening.
1.3.3
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.
1.3.4
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.
1.3.5
ALWAYS turn engine off and remove key from machine before
performing maintenance or making repairs.
1.3.6
ALWAYS handle blades carefully. The blades can develop sharp
edges which can cause serious cuts.
1.3.7
ALWAYS replace worn or damaged components with spare parts
designed and recommended by Wacker Corporation.
1.3.8
ALWAYS disconnect the spark plug on machines equipped with
gasoline engines, before servicing, to avoid accidental start-up.
1.3.9
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.
7
Safety Information
1.4
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CRT Repair
Label Locations—CRT 36
8
CRT Repair
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Safety Information
9
Safety Information
1.5
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CRT Repair
Label Locations—CRT 48 (manual steer)
10
CRT Repair
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Safety Information
11
Safety Information
1.6
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CRT Repair
Label Locations—CRT 48 (electric steer)
12
CRT Repair
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Safety Information
13
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.
No sparks, flames, or burning objects near the
machine. Shut off the engine before refueling.
Steering control. Refer to section Steering.
DANGER!
Before fueling, stop the engine. No sparks,
flames, or burning objects near the machine.
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14
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.
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15
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.
R e m o
o v e r h
P a n s
a p e r
G le it s
d a s G
G le it s
o d e r T
v e p a n f r o m
e a d .
c a n f a l l a n d
s o n i s h i t .
c h
e r
c h
o
d
e ib e
ä t u b
e ib e
v e r
v o
e r
k a
u r s
m
K o
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t r o w e l b e f o r e
c a u s e
B e
p f
f a
h e
t o
h ö
ll
n
d e a t h
n g lä t
h e g e
e n u n
w e n n
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t e r e
h o b
s c
P e r
l i f t i n g
m
o r s e r i o u s
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.)
a c h i n e
i n j u r y
i f
n t f e r n e n b e v o r
e n w ir d .
h w e r e V e r le t z u n g
s o n a l g e t r o f f e n w ir d .
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 .
1 1 8 6 8 8
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 .
WARNING!
Pinching hazard. Rotating machinery.
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16
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.
A nameplate listing the model number, item
number, revision number, 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, item number,
revision number, and serial number of the unit.
This machine may be covered by one or more
patents.
DANGER!
Engines emit carbon monoxide; operate only
in well-ventilated area.
Read the operator's manual for machine information.
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17
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.
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.
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CRT Repair
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Safety Information
19
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 (9.5)
Running Time
hrs.
2.7
Clutch
type
variable speed
Low Oil Shutdown
Engine Oil Capacity
Engine Lubrication
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yes
l (qt.)
oil grade
20
1.9 (2.0)
SAE 10W30 API CF-4, CF, SJ
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.)
2170 x 1170 x 1330
(86 x 46 x 52)
35-150
0-25
degrees
Gearbox
type
Gearbox Lubrication
type
heavy duty
Mobil Oil
SHC634
Mobil
Glygoyle 460
Mobil Oil
SHC634
Mobil
Glygoyle 460
1.83 (62) each
l (oz.)
Driveshaft
2032 x 1170 x 1320
(80 x 46 x 52)
splined universal joint
type
Operation
Troweling Width
with pans
(non-overlapping)
without pans
(overlapping)
without pans
(non-overlapping)
Troweling Area
with pans
(non-overlapping)
without pans
(overlapping)
without pans
(non-overlapping)
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mm (in.)
m2 (ft2)
21
1975 (78)
1975 (78)
2020 (80)
--
--
1905 (75)
1.8 (19)
1.8 (19)
2.0 (22)
--
--
1.6 (18)
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.
The weighted effective acceleration value, determined according to
ISO 2361-1 and ISO 5349, is:
-for whole body: 0,05 m/s2
-for hand/arm: 3,15 m/s2
The sound and vibration specifications were obtained with the unit
operating on fully cured, water wetted concrete at nominal engine
speed.
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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 (6.5)
10 (2.6)
Running Time
hrs.
2.5
Clutch
type
variable speed
Low Oil Shutdown
Engine Oil Capacity
Engine Lubrication
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yes
l (qt.)
oil grade
23
3.3 (3.5)
SAE 10W30 SH, SJ
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.)
2665 x 1395 x 1330
(105 x 55 x 52)
25-150
0-25
degrees
Gearbox
type
Gearbox Lubrication
type
heavy duty, fan cooled
Mobil Oil
SHC634
Mobil
Glygoyle 460
Mobil Oil
SHC634
Mobil Glygoyle
460
1.83 (62) each
l (oz.)
Driveshaft
2530 x 1397 x 1328
(100 x 55 x 52)
splined universal joint
type
Operation
Troweling Width
with pans
(non-overlapping)
without pans
(overlapping)
without pans
(non-overlapping)
Troweling Area
with pans
(non-overlapping)
without pans
(overlapping)
without pans
(non-overlapping)
wc_td000179gb.fm
mm (in.)
2465 (97)
2465 (97)
2515 (99)
--
--
2413 (95)
3 (32)
3 (32)
3.2 (34)
--
--
2.8 (30)
m2 (ft2)
24
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.
The weighted effective acceleration value, determined according to
ISO 2361-1 and ISO 5349, is:
•
for whole body 1.29 m/s2
•
for hand/arm 2.85 m/s2
The sound and vibration specifications were obtained with the unit
operating on fully cured, water wetted concrete at nominal engine
speed.
wc_td000179gb.fm
25
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
24.6 (6.5)
10 (2.6)
Running Time
hrs.
2.5
Clutch
type
variable speed
Low Oil Shutdown
Engine Oil Capacity
Engine Lubrication
Driveshaft
wc_td000179gb.fm
yes
l (qt.)
oil grade
type
26
3.3 (3.5)
SAE 10W30 SH, SJ
splined universal joint
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.)
2665 x 1395 x 1330
(105 x 55 x 52)
25-150
0-25
degrees
Gearbox
type
Gearbox Lubrication
type
2530 x 1397 x 1328
(100 x 55 x 52)
heavy duty, fan cooled
Mobil Oil
SHC634
Mobil
Glygoyle 460
Mobil Oil
SHC634
Mobil
Glygoyle 460
1.83 (62) each
l (oz.)
Operation
Troweling Width
with pans
(non-overlapping)
without pans
(overlapping)
without pans
(non-overlapping)
Troweling Area
with pans
(non-overlapping)
without pans
(overlapping)
without pans
(non-overlapping)
wc_td000179gb.fm
mm (in.)
m2 (ft2)
27
2465 (97)
2465 (97)
2515 (99)
--
--
2413 (95)
3 (32)
3 (32)
3.2 (34)
--
--
2.8 (30)
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.
The weighted effective acceleration value, determined according to
ISO 2361-1 and ISO 5349, is:
•
for whole body 1.29 m/s2
•
for hand/arm 2.85 m/s2
The sound and vibration specifications were obtained with the unit
operating on fully cured, water wetted concrete at nominal engine
speed.
wc_td000179gb.fm
28
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. Each model
also includes an operator presence system and an engine with low-oil
shutdown protection.
Wacker CRT Riding Trowels are the most technically advanced
trowels on the market today. With proper maintenance and use, your
Riding Trowel will provide you with years of service.
3.2
Information Regarding Operation
The information regarding the operation of the machine included in this
manual is condensed. Refer to the Operator’s Manual for complete
operating instructions. Always read, understand, and follow the
procedures in the Operator’s Manual when operating the machine.
wc_tx000589gb.fm
29
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.fm
30
CRT Repair
3.4
Ref.
Operation
Features and Controls—CRT 48 Electric Steer
Description
Ref.
Description
a
Right pitch control
q
Work light switch
b
Water tank
r
DC accessory outlet
c
Joystick
s
Engine keyswitch
d
Operator’s seat with “operator
presence” switch
t
Hour meter
e
Left pitch control
u
Water spray control
f
Rear work light (one each side)
v
Oil pressure indicator light
g
Control panel
w
Alternator charging indicator light
h
Fuel tank
x
Coolant temperature indicator
light
m
Work light (one each side)
y
Status OK indicator light (green)
n
Foot pedal (throttle control)
z
Status error indicator light (red)
o
Engine choke control
wc_tx000589gb.fm
31
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.
Note: If the engine is cold, pull out the choke control knob fully.
CAUTION: Cranking the engine for more than 5 seconds can cause
starter damage. If the engine fails to start, release the keyswitch and
wait 10 seconds before operating the starter again.
Note: The engine has an oil alert switch designed to stop the engine
automatically if the oil level gets too low. If engine will not start, or stops
during operation, check engine oil level.
3.6.2
3.7
Allow the engine to warm up before operating the trowel.
Stopping
To stop trowel movement, return joystick(s) or control levers to their
neutral position and release pressure on the throttle foot pedal.
To stop the engine, turn the keyswitch to “O” (off).
wc_tx000589gb.fm
32
CRT Repair
wc_tx000589gb.fm
Operation
33
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.
•
Check and tighten external hardware.
•
Pressure wash all surfaces until free of concrete.2
•
Every
20
hrs.
Check oil level in gearboxes.
•
Grease gearbox, drive system and pitch posts
fittings.
•
Grease control linkage.3
•
Check drive belt for wear.
Every
50
hrs.
Every
100
hrs.
Every
200
hrs.
Every
300
hrs.
•
Change engine oil.4
•
Check fuel filter.
•
Clean and check spark plug.
•
Replace oil filter.
•
Replace spark plug.
•
Replace fuel filter.
•
Replace gearbox pressure relief valve.
•
Replace oil in gearboxes.
•
1
Check engine oil twice daily (every 4 hours).
Pressure wash immediately after use.
3 Manual steering models only.
4
Change engine oil after first 20 hours of operation.
2
wc_tx000581gb.fm
34
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.
•
Check and tighten external hardware.
•
Pressure wash all surfaces until free of
concrete.2
•
Check coolant level.
•
Every
20
hrs.
Check oil level in gearboxes.
•
Grease gearbox input shaft fitting
•
Grease control linkage.3
•
Check drive belt for wear.
Every
50
hrs.
Every
100
hrs.
Every
200
hrs.
Every
300
hrs.
•
Change engine oil.4
•
Check fuel filter.
•
Clean and check spark plug.
•
Replace oil filter.
•
Check fan belt.
•
Replace spark plug.
•
Replace fuel filter.
•
Replace gearbox pressure relief valve.
•
Replace oil in gearboxes.
•
Change coolant.
•
1 Check
engine oil twice daily (every 4 hours).
2
Pressure wash immediately after use.
wc_tx000581gb.fm
3
4
Manual steering models only.
Change engine oil after first 20 hours of operation.
35
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.
Wipe the threads dry on both the gearbox and the oil fill plug, apply
Loctite 545 or equivalent to the oil fill plug threads, replace the oil fill
plug and torque to 16–20 Nm (12–15 ft.lbs.).
CAUTION: DO NOT mix types of gear oil. DO NOT overfill the gearbox
with oil. Damage to the gearbox may occur if oils are mixed, or if the
gearbox is overfilled. See Technical Data for oil quantity and type.
To change gearbox oil:
4.3.1
Place a container of sufficient capacity (approximately 3.8 l [1 gallon])
under each gearbox.
4.3.2
Remove the gearbox oil drain plug (c) and allow the oil to drain out. It
may be necessary to remove the gearbox oil fill plug(s) to facilitate
draining. After most of the oil has drained out, tip the back of the trowel
upwards to allow the remaining oil to drain out.
4.3.3
After all the oil has drained out, wipe the threads dry on both the
gearbox and the oil drain plug, apply Loctite 545 or equivalent to the oil
drain plug threads, and replace the gearbox oil drain plug.
Note: Dispose of used gear oil in accordance with environmental
protection legislation.
4.3.4
With the trowel level, fill the gearbox with approximately 1.83 l (62 oz.)
synthetic gear oil through the oil fill plug as described above.
4.3.5
Wipe the threads dry on both the gearbox and the oil fill plug, apply
Loctite 545 or equivalent to the oil fill plug threads, replace the oil fill
plug(s), and torque all plugs to 16-20Nm (12–15 ft.lbs.).
Each gearbox has a pressure relief valve (a) which can become
clogged over time and should be replaced every 300 hours. Failure to
replace the valve can result in oil leakage from the gearbox shaft seals.
wc_tx000581gb.fm
36
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.fm
37
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.
4.5.4
Raise the trowel very slightly to take the weight off of the blades. Use
a fork lift or dolly jacks.
4.5.5
Slide the blades to align them with the screw holes (d).
Trowel blades may be sharp! Use adequate protection to keep from
cutting skin or clothing!
CAUTION
4.5.6
Lower the trowel so the arms are securely against the blades.
4.5.7
Secure the screws into the screw holes (d). Dip the threads of the
screws in grease prior to installation. This will prevent concrete from
cementing the screws in place and make removal of the blades easier
later on.
Note: Do not operate the trowel unless all blades are either in the
overlapping or non-overlapping position.
To switch the position of the blades from overlapping to nonoverlapping, reverse the process.
Blade Arm Adjustment Procedure
To eliminate wobble:
wc_tx000581gb.fm
4.5.1
Pitch the blades flat.
4.5.2
Tighten lock nut located at the bottom of each pitch cable. Maximum
cable play should be no more than 3.18 mm (.125”) or the width of the
cable.
4.5.3
Set gap on all adjustable links to 4.58 mm (.180”).
38
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. Remember, the right-hand trowel blades turn
counterclockwise; the left-hand blades turn clockwise.
wc_tx000581gb.fm
39
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.
WARNING
wc_tx000581gb.fm
DO NOT lift the trowel by the guard rings or any part of the trowel other
than the lifting fixture, as the component may fail, causing the trowel to
fall, possibly injuring bystanders.
40
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.
4.8.3
Set gap to 0.76 mm (0.030 in).
4.8.4
Tighten spark plug securely.
CAUTION: A loose spark plug can become very hot and may cause
engine damage.
4.9
Spark Plug—CRT 48
Clean or replace spark plug as needed to ensure proper operation.
Refer to the engine Owner’s Manual.
Recommended Plug: NGK ZGR5A, DENSO J16CR-U
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.
4.9.1
Remove spark plug and inspect it.
4.9.2
Replace plug if the insulator is cracked or chipped. Clean spark plug
electrodes with a wire brush.
4.9.3
Set gap to 0.70 mm (0.028 in).
4.9.4
Tighten spark plug securely.
CAUTION: A loose spark plug can become very hot and may cause
engine damage.
wc_tx000581gb.fm
41
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). Remove both elements (b, c) and
inspect them for holes or tears. Replace damaged elements.
4.10.2
Wash foam element (b) in solution of mild detergent and warm water.
Rinse thoroughly in clean water. Allow element to dry thoroughly.
Do not put oil on the foam element.
4.10.3
Tap paper element (c) lightly to remove excess dirt. Replace paper
element if it appears heavily soiled.
a
b
c
wc_gr000154
wc_tx000581gb.fm
42
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
4.11.5
Install cover and lock clamps.
CAUTION: NEVER run engine without air cleaner. Severe engine
damage will occur.
wc_tx000581gb.fm
43
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.
4.12.3
Fill engine crankcase with recommended oil to the upper limit mark on
the dipstick (c).
Oil capacity: 1.18 l (1.25 qt.).
4.12.4
Install oil fill cap and dipstick securely.
4.12.5
To replace the oil filter, remove the installed oil filter after oil has been
drained. Apply a thin coat of oil to the rubber gasket of the replacement
oil filter. Screw the filter on until it just contacts the filter adapter, then
turn it an additional 22.24mm (7/8in) turn. Refill with oil as described
above.
a
c
b
wc_gr000155
wc_tx000581gb.fm
44
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.).
4.13.3
Fill engine crankcase with recommended oil until the level is between
“L” and “F” on the dipstick (c).
Oil capacity: 3 l (3.2 qt.).
wc_tx000581gb.fm
4.13.4
Install oil fill cap.
4.13.5
To replace the oil filter (d), remove the installed oil filter after oil has
been drained. Apply a thin coat of oil to the rubber gasket of the
replacement oil filter. Screw the filter on until it just contacts the filter
adapter, then turn it an additional ½ turn. Refill with oil as described
above.
45
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.
The movement of each
gearbox is controlled by
“stops” to provide the correct
relationship of the control arm
movement to machine
movement. Excessive
pressure on control arms in
any direction will not increase
reaction time and can
damage steering controls
causing machine to wobble.
Trowel arm(s) bent.
Replace trowel arm(s).
Trowel blade(s) bent.
Replace trowel blade(s).
Main shaft(s) bent due to
machine being dropped.
Replace main shafts(s).
Drive belt broken.
Replace drive belt.
Vacuum between bottom of
blades and surface of
concrete.
Change pitch on blades to
break suction.
Key sheared in the main
shaft.
Replace damaged key.
46
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.
Align blades so that one set
represents a (+) and the other
an (x) when viewed from
above.
Sheared key.
Check all keys in drive
system.
Loose clutch.
Tighten clutch.
47
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.
•
Slide the wiring harness from the two harness guides.
•
Remove the bolts securing the beltguard to the engine and
remove the beltguard.
5.1.4
Remove the bolts (d), washers (e), and nuts (f) securing each bearing
flange (c) to the machine.
5.1.5
For CRT 48: On the side closest to the clutch pulley, remove the bolts
(b) and shims (if included) holding the inside portion of the universal
joint to the drive shaft flange (a).
For CRT 36: Remove the bolts (b) and shims (if included) holding each
inner universal joint to the drive shaft flange(s) (a).
5.1.6
Lift the pulley, the shaft, and the bearing flanges high enough so that
the belt can clear the components; once in position, slide the belt off
the pulley and remove it from the machine.
5.1.7
Install a new belt in the same manner.
5.1.8
Align the pulley with the clutch so that the offset and center distances
match the values shown.
5.1.9
Secure the bearing flanges (c) to the machine with bolts (d), washers
(e), and nuts (f). Torque the bolts to 134 Nm (99 ft.lbs.).
5.1.10
Secure the universal joints to the shaft flanges (a) with bolts (b).
Torque the bolts to 13 Nm (10 ft.lbs.).
48
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.fm
49
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). Using a puller, remove the bearing flanges (g) (including
the shaft flanges) from the drive shaft. Also remove the keys (j).
5.2.4
Remove the setscrews from the bearing flanges.
5.2.5
Using a press, press the shaft flanges (l) from the bearing flanges (g).
5.2.6
Slide the small spacer (p), the pulley (n), and the large spacer (o) off
the drive shaft. Remove the key (m).
Assembly:
wc_tx000582gb.fm
5.2.7
Apply anti-seize compound to the mounting areas of the drive shaft (p).
5.2.8
Install the key (m), and slide the spacer (o) and the pulley (n) onto the
drive shaft.
5.2.9
Press the shaft flanges (l) into the bearing flanges (g) and tighten the
setscrews.
5.2.10
Install the keys (j) onto the drive shaft. Install the bearing flange/shaft
flange assemblies. Apply Loctite 243 to the center bolts (i) and reinstall
them and the washers (k). Torque the center bolts to 10 Nm (7 ft.lbs.).
5.2.11
Attach the inside ends of the universal joints and the shims (h) to the
shaft flanges with screws (b). Torque the screws to 10 Nm (7 ft.lbs.).
5.2.12
Position the drive belt around the pulley.
5.2.13
Place the assembled drive shaft into the machine.
5.2.14
Apply Loctite 243 or an equivalent to the bolts (d) and reinstall each
bearing flange (g) with the bolts, washers (e), and nuts (f). Torque the
bolts to 135 Nm (99 ft.lbs.).
5.2.15
Apply Loctite 243 to the screws (a) and attach the outside end of each
universal joint (c) to the gearboxes. Torque the screws to 10 Nm (7
ft.lbs.).
50
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.fm
51
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.
The rotors (“spiders”), which hold the blades, require proper timing so
they will not interfere with each other during operation.
Anytime the drive line is worked on or gearboxes are removed, timing
of the spiders should be checked.
To time the spiders:
wc_tx000583gb.fm
6.1.1
Elevate the trowel off the ground. Use either the dolly jack wheels or
place the trowel on blocks.
6.1.2
Disconnect one of the universal joints from one of the gearboxes.
6.1.3
Rotate the input shaft of the disconnected gearbox until the blades
align as shown.
6.1.4
Reconnect the universal joint.
52
CRT Repair
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Spiders and Gearboxes
53
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).
•
Loosen the clamp that secures the water line (b) to the water tank
and remove the water line from the water tank.
•
Remove the two bolts (c) located underneath the water tank and
lift the water tank from the frame.
Preliminary steps for the left-side gearbox:
•
Close the fuel valve (d). Loosen the clamp and remove the fuel
hose (e) from the fuel tank (f). Catch any fuel that may drip from
the fuel hose with an appropriate container.
•
Remove the bolts (g) (and spacers if equipped) located underneath the fuel tank and lift the fuel tank from the frame.
f
a
g
c
e
d
g
b
wc_gr003420
wc_tx000583gb.fm
6.2.6
Remove the nut from each pitch cable (h) and pull the cable out of the
pitch yoke.
6.2.7
Remove the screws that secure the pitch control assembly (i) and
remove the pitch control assembly.
6.2.8
Disconnect the wiring (j) to the work lights.
54
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.
n
k
l
l
j
i
h
l
k
m
wc_gr003421
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55
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.
6.2.17
Connect the work light harness.
6.2.18
For the right-side gearbox:
6.2.19
wc_tx000583gb.fm
•
Position the water tank onto the frame and secure it with bolts
from underneath.
•
Attach the water line to the water tank and tighten the clamp.
For the left-side gearbox:
•
Position the fuel tank on the frame and secure it with bolts from
underneath.
•
Slide the fuel hose onto the fitting and tighten the clamp.
6.2.20
Secure the drive train to the gearbox. See Drive Line Teardown and
Rebuild.
6.2.21
Align the blades. See section Gearbox Basics.
56
CRT Repair
Spiders and Gearboxes
n
k
l
l
j
i
h
l
k
m
wc_gr003421
wc_tx000583gb.fm
57
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.
6.3.3
On machines with stabilizer rings, remove the shoulder bolts from the
ends of the arms and remove the stabilizer rings (a).
6.3.4
Remove the shoulder bolts (b) from the lift ring assembly. Do not
change the position (rotate) of the lifting links (c) unless readjustment
is being done.
6.3.5
There are two styles of arms used. One style uses a locking pin to
retain the arm to the spider. This style is characterized by the hex nut
(d) into which the grease fitting is installed. If your trowel has this style
arm, remove the locking pin (with the grease fitting). On styles with just
the grease fitting (e), the grease fitting may be left in place.
6.3.6
Remove the cotter pin (f), the pivot pin (g), and the blade yoke (h) from
the machine. Remove the roller guides (i) if necessary.
6.3.7
Remove the plug (j) from the spider. Remove the bolt (k) and washer
(l) and remove spider (m) from the gearbox.
6.3.8
Remove the lift ring assembly (n).
6.3.9
Repeat these steps for the opposite gearbox.
58
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.fm
59
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. Tighten the
bolt so that the roller guides are tight, then back off the bolt just enough
so the roller guides can turn.
6.3.13
Install the arms into the spider.
6.3.14
Secure the blades to each arm with three screws.
CAUTION
wc_tx000583gb.fm
The blades may have sharp edges that can cut. Wear an appropriate
pair of gloves when installing the blades.
6.3.15
Secure the lifting links to the lift ring assembly with the shoulder bolts
(b).
6.3.16
On machines with stabilizer rings (a), secure the stabilizer ring to the
arms with the shoulder bolts.
6.3.17
Install the gearbox(es) to the machine. See section Gearbox Removal
and Installation.
6.3.18
Adjust the blade pitch. See section Adjusting Blade Pitch.
60
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.fm
61
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).
6.4.6
Press the bearing (e) from the bearing holder.
6.4.7
Press the bushing (f) from the lift ring.
6.4.8
Remove the roller guides (g) if necessary.
Assembly:
wc_tx000583gb.fm
6.4.9
Press the bushing (f) into the lift ring.
6.4.10
Press the bearing (e) into the bearing holder (d).
6.4.11
Apply anti-seize to the threads and bearing area of the lift ring (x).
6.4.12
Slide the bearing holder and the bearing onto the lift ring.
6.4.13
Thread the lift cap (b) onto the lift ring and tighten it.
6.4.14
Install the roller guides (g) if they were removed. When installing the
roller guides, use Loctite 271 or an equivalent on the bolt. Tighten the
bolt so that the roller guides are tight, then back off the bolt just enough
so the roller guides can turn.
6.4.15
Install the lift assembly onto the spider.
62
CRT Repair
Spiders and Gearboxes
b
g
g
f
b
c
d
x
a
e
g
wc_gr003424
wc_tx000583gb.fm
63
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.
6.5.3
Check the angle of each blade by placing an angle gauge (a) along the
front edge of the blade.
6.5.4
Adjust each blade arm as needed to match the measurement. To
adjust the blade arms, remove the shoulder bolt (b) and turn the link
(c) to increase or decrease the blade angle.
Note: All blades must be set at the same angle for correct operation.
6.5.5
Once all blade angles have been set, apply Loctite 243 or an
equivalent to each shoulder bolt and tighten it. Torque the shoulder
bolts to 24 Nm (18 ft.lbs.).
Combination square method (2):
6.5.6
Set the trowel on a flat surface and install the new blades.
6.5.7
Turn the blade pitch controls until the blades are at one-half the
maximum pitch.
6.5.8
Position a combination square (d) as shown. With the combination
square positioned against the front (raised) edge of the trowel blade,
slide the moveable portion of the combination square down until it
contacts the top edge of the trowel blade. Once in place, lock the
moveable portion in place.
6.5.9
Check each of the other blades against this measurement.
6.5.10
Adjust each blade arm as needed to match the measurement. To
adjust the blade arms, remove the shoulder bolt (b) and turn the link
(c) to increase or decrease the blade angle.
Note: All blades must be set at the same angle for correct operation.
6.5.11
wc_tx000583gb.fm
Once all blade angles have been set, apply Loctite 243 or an
equivalent to each shoulder bolt and tighten it. Torque the shoulder
bolts to 24 Nm (18 ft.lbs.).
64
CRT Repair
Spiders and Gearboxes
1
2
a
d
b
c
wc_gr003425
wc_tx000583gb.fm
65
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.
Open or remove pressure relief valve (c) if needed.
Note: In the interests of environmental protection, place a plastic sheet
and a container under the machine to collect any liquid that drains off.
Dispose of this liquid in accordance with environmental protection
legislation.
6.6.4
wc_tx000583gb.fm
For 48-inch models:
•
Remove the screws (e) and washers that secure the protective
guard (d) and remove the protective guard from the gearbox.
•
Remove the center screw (f) and washer that secure the fan (g)
and remove the fan.
6.6.5
Remove the screws that secure each seal cover (h) to the gearbox and
remove the seal covers. Also remove the shim(s) and the O-ring. Press
the seal from each cover.
6.6.6
Remove the bolts (i) from the top cover (j) and remove the top cover.
Also remove the shim(s) (k) and the O-ring (l).
6.6.7
Remove the output shaft (m) from the gearbox. To do so, rotate the
input shaft (n) while driving out the output shaft with a rubber hammer.
6.6.8
Support the output gear (o) in a press. Press the output shaft from both
the output gear and the upper bearing (p).
6.6.9
Remove the key and press the lower bearing (q) from the output shaft.
6.6.10
Remove the input shaft (n) from the gearbox. To do so, drive it out (in
either direction) of the gearbox with a rubber hammer. The
corresponding outer bearing race will also be driven out in the process.
To remove the opposite-side bearing race, reinsert the shaft and using
the rubber hammer, drive the bearing race out of the gearbox by
striking the input shaft.
6.6.11
Press the bearings (r, s) off the input shaft (n).
6.6.12
Using a hammer-type puller (t), remove the outer bearing race from the
gearbox cover (CT Trowel gearbox cover shown). Use the same
technique to remove the outer bearing race from the gearbox.
6.6.13
Remove the two seals (v) from the gearbox.
66
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.fm
67
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).
6.7.6
Press the output gear (o) and the upper bearing (p) onto the output
shaft.
6.7.7
Pack the upper bearing of the output shaft with grease. Oil the lower
bearing of the output shaft.
6.7.8
Insert the output shaft into the gear box.
6.7.9
Install the outer bearing races of the input shaft into the gearbox by
tapping them in with a rubber mallet. Tap them in so that they are flush
with the outside of the gearbox housing.
6.7.10
On the coupling side of the input shaft, install the O-ring (u) and seal
(x) into the cover (v). Then, install the cover and any shims (w) that
were removed to the gearbox with screws. Torque the screws to 25
Nm (18 ft.lbs.).
6.7.11
On the fan side of the input shaft, install the O-ring and seal into the
cover (h). Then, install the cover and any shims that were removed.
Tap each end of the input shaft with a rubber mallet to set the bearings.
Check the shaft for end play. The maximum allowable end play is 0.05
mm (0.002 in.). Add or remove shims as needed. Once set, torque the
screws to 25 Nm (18 ft.lbs.).
6.7.12
Install the O-ring and the pressure relief valve (if it was removed) to the
top cover. Check the shaft for side play. The maximum allowable side
play is 0.05 mm (0.002 in.). Add or remove shims as needed. Once set,
apply Loctite 243 or an equivalent to the screws and torque the screws
to 86 Nm (63 ft.lbs.).
6.7.13
Apply Loctite 545 or an equivalent to the oil drain plug and install the
oil drain plug.
6.7.14
With the gearbox level, fill it with approximately 1.8 liters (62 oz.) of
Glycoyle synthetic gear oil. DO NOT overfill the gearbox with oil. Wipe
the threads of the gearbox and the oil fill plug dry. Apply Loctite 545 or
an equivalent to the fill plug and install it into the gearbox. Torque the
fill plug to 20 Nm (15 ft.lbs.).
6.7.15
For 48-inch models:
•
Install the fan (g) with the center screw (f) and washer.
•
Install the protective guard (d) with screws (e) and washers.
68
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.fm
69
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.
7.1.6
Remove the screws (n).
7.1.7
Turn (unscrew) the handle (r) to remove it from the pitch control tube
(i).
7.1.8
Remove the two spring-loaded balls and springs (c) from the housing.
7.1.9
If replacing the cable, remove the index bolt (h) and spacer from the
cable tube (f) and slide it out of the pitch control tube.
7.1.10
Press the pin (k) out of the pitch control tube far enough to remove the
cable.
Installation:
wc_tx000584gb.fm
7.1.11
If the pitch cable (g) was removed, insert the pitch cable into the cable
tube (f) and secure it with the pin (k).
7.1.12
Slide the cable tube (f) into the pitch control tube (i). Apply Loctite 243
or an equivalent to the index bolt (h) and install it and the spacer into
the cable tube.
Note: There are specific cable tubes and screws for each side (left or
right) of the machine. Be sure to use the correct ones for the particular
side of the machine you are working on.
7.1.13
Lightly grease the spring-loaded balls and the springs (c) and install
them into the pitch control tube.
7.1.14
Lightly grease the threaded shaft (e) and screw it into the cable tube
(f).
7.1.15
Gently seat the crank handle assembly onto the spring-loaded balls
(c). Apply Loctite 243 or an equivalent to the screws (n) and secure the
crank handle assembly to the pitch control tube. Torque the screws to
2.94 Nm (26 in.lbs.).
70
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).
With the handle cranked to the lowest position and the blades flat (0°
pitch), lift the yoke (m) until it contacts the rollers. Then, thread on the
locknut (t) until it contacts the pitch cable mount (l).
7.1.18
Be sure that the blades are flat and all slack is removed from the cable.
r
n
e
f
k
g
c
d
h
i
a
b
m
t
wc_tx000584gb.fm
l
wc_gr001585
71
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.
Note: On some models you will need to disconnect the water pump
before removing the front grill.
7.2.5
Remove the bolts (d, e) and the spacers (f) from the bottom of each
handle mount (c).
7.2.6
Remove the nuts (z) and remove each handle mount.
7.2.7
Remove the bolt (g) and the nut (h) from each pivot bracket (i) on the
end of the control shafts (aa).
7.2.8
Remove the screws (j) and nuts (k) securing the outside bearings (l)
to the frame and remove the outside bearings and the control shafts.
7.2.9
Remove the screws (m) and the nuts (n) from the center bearings (o)
and remove the center bearings.
Installation:
wc_tx000584gb.fm
7.2.10
Grease the center bearings (o) and attach with screws (m) and nuts
(n). Torque the screws to 24 Nm (18 ft.lbs.).
7.2.11
Install one side of the control shaft into the center bearings, then
secure the other end by attaching the outside bearings (l) with screws
(j) and nuts (k). Torque the screws to 24 Nm (18 ft.lbs.).
7.2.12
Secure the control shaft to the pivot link (q) with bolt (g) and nut (h) at
pivot bracket (i).
7.2.13
Secure the handle mounts (c) to the control shafts with nuts (z).
7.2.14
Attach each steering lever (d) to the handle mounts with bolts (d, e)
and spacers (f).
7.2.15
Reconnect the wiring harness (a).
7.2.16
Attach the front grill and reconnect the water pump if it was
disconnected.
72
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.fm
e
73
wc_gr003443
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.
Note: On some models you will need to disconnect the water pump
before removing the front grill.
7.3.5
Remove the bolts (d, e) and the spacers (f) from the bottom of each
handle mount (c).
7.3.6
Remove the nuts (z) and remove each handle mount.
7.3.7
Remove the bolt (g) and the nut (h) from each pivot bracket (i) on the
end of the control shafts (aa).
7.3.8
Remove the screws (j) and nuts (k) securing the outside bearings (l)
to the frame and remove the outside bearings and the control shafts.
7.3.9
Remove the screws (m) and the nuts (n) from the center bearings (o)
and remove the center bearings.
Installation:
wc_tx000584gb.fm
7.3.10
Grease the center bearings (o) and attach with screws (m) and nuts
(n). Torque the screws to 24 Nm (18 ft.lbs.).
7.3.11
Install one side of the control shaft into the center bearings, then
secure the other end by attaching the outside bearings (l) with screws
(j) and nuts (k). Torque the screws to 24 Nm (18 ft.lbs.).
7.3.12
Secure the control shaft to the pivot link (q) with bolt (g) and nut (h) at
pivot bracket (i).
7.3.13
Secure the handle mounts (c) to the control shafts with nuts (z).
7.3.14
Attach each steering lever (d) to the handle mounts with bolts (d, e)
and spacers (f).
7.3.15
Reconnect the wiring harness (a).
7.3.16
Attach the front grill and reconnect the water pump if it was
disconnected.
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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.fm
e
75
wc_gr003444
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
7.5
•
Extend the linkage to adjust the control arms forward.
•
Shorten the linkage to adjust the control arms backward.
After the control arms have been adjusted to the desired position,
tighten the jam nuts (b). Torque the jam nuts to 75 Nm (55 ft.lbs.).
Adjusting the Right-hand Control Arm (right or left)
See Graphic: wc_gr003458
The right-hand arm should be set to be perfectly parallel to the lefthand arm. Should the arms come out of adjustment, adjust the righthand arm as follows:
wc_tx000584gb.fm
7.5.1
Remove the nut and bolt (c).
7.5.2
Loosen the jam nuts (d).
7.5.3
Drop the horizontal linkage (e) down to clear the bracket.
7.5.4
Shorten the linkage to move the control arm to the left.
7.5.5
Extend the linkage to move the control arm to the right.
7.5.6
After the control lever has been adjusted to the desired position,
reassemble the nut and the bolt (c) and tighten the jam nuts (d).
76
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.fm
77
y
wc_gr003458
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. Connecting the adjustable link in the front hole will
decrease the effort required by the operator to move the steering arms
but will increase the amount of travel of the steering arms required.
Connecting the adjustable link in the rear hole will increase the amount
of effort required to move the steering arms but will lessen the amount
of travel required. To adjust the steering arm responsiveness, carry out
the following procedure:
wc_tx000584gb.fm
7.6.1
Locate the forward/reverse steering pivots (r) and the left/right
adjustable links (a).
7.6.2
If necessary, adjust the forward/reverse steering pivots (r) so that they
are horizontal when the machine is at rest. To do so, loosen the jam
nuts on the pivot links (q and y) and turn the links in or out to level the
steering pivots. Once the steering pivots are horizontal, torque the jam
nuts to 77 Nm (57 ft.lbs.).
7.6.3
Disconnect the attaching bolts (s) and nuts (t). Move the adjustable
link to the desired hole in the steering pivots and reattach the bolts and
nuts. Torque the nuts (t) to 75 Nm (55 ft.lbs.).
7.6.4
If the connection point of the adjustable links is changed at the steering
pivots, a corresponding change in the connection point at the upper
pivot bracket (i) will also need to be made. Disconnect the attaching
bolts (g) and nuts (h). Move the adjustable link to the desired hole in
the upper pivot bracket and reattach the bolts and nuts. Torque the
nuts (t) to 75 Nm (55 ft.lbs.).
78
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.fm
79
y
wc_gr003458
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:
7.7.1
Loosen the jam nuts (d) on the left/right pivot link (e) and turn the pivot
link until the left pivot bracket (v) is horizontal. Once the pivot link is
horizontal, torque the jam nuts to 75 Nm (55 ft.lbs.).
7.7.2
If the steering arms are not centered (90° to the pivot bracket), loosen
the jam nuts on the offset pivot link (w) and remove the bolt (x) from
the bottom of the steering handle. Adjust (turn) the handle mount (y)
until the steering arms are centered, then reinstall the bolts into the
bottom of the steering arms. Torque the jam nuts on the offset pivot link
to 75 Nm (55 ft.lbs.).
If the operator prefers more distance between the steering arms,
adjust the steering handle spacing. To do so, carry out the following
procedure:
wc_tx000584gb.fm
7.7.3
Loosen the jam nuts on the offset pivot link (w).
7.7.4
Remove the bolts (x, y) from the bottom of the handle mounts.
7.7.5
Adjust (turn) the handle mounts to increase or decrease the width
between the control arms. Then, tighten the jam nuts on the offset pivot
link. Torque the jam nuts and bolts to 75 Nm (55 ft.lbs.).
80
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.)
between center lines of tie-rods
g
19.37 cm (7-5/8 in.)
between center lines of tie-rods
d
CRT 48: 48.26 cm (19 in.)
CRT 36: 35.88 cm (14-1/8 in.)
between center lines of tie-rods
wc_tx000584gb.fm
81
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.
Control of power to the actuator motors is done through electric signals
(voltages) sent and received between the major components of the
system: the joysticks, the control board, the actuator motors, and the
load pins.
When the ignition key is in the ON position, the joysticks receive
12VDC from the control board and feed back 0–5VDC depending on
their position. In the home position (neutral), they hold a 2.5VDC
charge. In the full-forward position, the voltage approaches 5VDC; in
the full-backward position, the voltage drops to approximately 0.5VDC.
The load pins are also fed 12VDC from the control board and feed back
0–5VDC. The amount of voltage fed back to the control board depends
on the amount of force applied to them by the actuator. The greater the
pressure, the greater the voltage feedback to the control board. In the
home position (neutral) the load pins are preloaded and hold a 2.5VDC
charge. As the angle of the gearbox changes, so does the pressure on
the load pin. When the gearboxes are tilted forward, the pressure on
the load pins decreases. This decrease in pressure translates into a
decrease in the feedback voltage to the control board. When the
gearboxes are tilted backward, the pressure on the load pins
increases. This increase in pressure increases the feedback voltage to
the control board.
For every feedback voltage from the joysticks, the control board is
programmed to expect a specific feedback voltage from the load pins.
For every position of the joysticks, the control board will send voltage
to the appropriate actuator motor until the pressure on the load pin
translates into the expected feedback voltage for the given position; at
which point, voltage to the actuator motor ceases and actuator
movement stops.
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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.fm
Ref.
83
Description
0–5V
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. This condition
can occur if a load pin is damaged, its wiring has an open circuit, or its
wiring has a short circuit. The “limp home” mode is designed to allow
the operator to continue steering the trowel, at a reduced level of
control, until a repair can be made. In the “limp home” mode, the
actuators are still driven in or out by joystick movement; however, the
actuator does not return to the home (center) position when the
joystick is released. There is no automatic home (center) position for
the actuators; the joysticks must be used for every actuator movement.
For example, if the joysticks are positioned in a full forward position,
the microprocessor will send voltage to the actuator motor. With no
feedback from the load pin, the microprocessor cannot tell when the
actuator has reached the desired position and thus will continue to
send voltage to the actuator motor as long as the joystick is moved
from its home position. When the joystick is released, the joystick
returns to its home position; however, the actuators do not. They will
remain in the full-forward position. The joysticks must be used to
manually bring the actuators back to neutral by oversteering in the
opposite direction.
The trowel’s steering system is calibrated at the factory and should not
normally require calibrating. However, if a damaged load pin is
detected, calibration may be required. Calibration may be done by
contacting your local Wacker Corporation authorized service dealer.
7.11 Error Codes
The red indicator light (b) is used to communicate system faults. A
specific sequence of flashes of the red indicator light is used to identify
each fault. The sequence of flashes is known as the error code. There
are 17 distinct error codes. Error code sequence:
b
wc_gr003381
wc_tx000584gb.fm
•
long pause
•
1 to 4 flashes
•
short pause
•
1 to 3 flashes
•
short pause
•
1 to 5 flashes
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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.
Description
111
Right control fault
231
Left load pin open circuit
121
Side control fault
232
Left load pin short circuit
131
Left control fault
311
Right joystick open circuit
211
Right load pin open circuit
312
Right joystick short circuit
212
Right load pin short circuit
321
Left joystick open circuit
213
Right load pin bent
322
Left joystick short circuit
221
Side load pin open circuit
414
Control board over temperature
(above 80°C / 176°F)
222
Side load pin short circuit
415
Low battery voltage
223
Side load pin bent
When an error code is displayed via the red indicator light, record the
error code. Before in-depth troubleshooting, carry out the following
procedure:
7.11.1
7.11.2
7.11.3
wc_tx000584gb.fm
Turn the ignition switch OFF and then back ON again. Check the
function of the steering system on all three circuits: right, side, and left.
•
If the red indicator light is no longer flashing and the system is
functioning, no further action is required.
•
If the red indicator light is still flashing, turn the ignition switch
OFF and continue.
Use a digital multimeter to check the battery voltage. It must be over
11VDC for proper operation.
•
If the battery voltage is under 11VDC, charge or replace it.
•
If the battery voltage is 11VDC or more, continue.
Check the 70A maxi-fuse for the steering control system actuators. It
is located under the seat pedestal above the relays and ignition
module cover.
•
If the 70A maxi-fuse is blown, replace it.
•
If the 70A maxi-fuse is not blown, continue with in-depth troubleshooting.
85
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. Move the right joystick back and forth from
its full-forward to its full-reverse positions and watch for movement of
the right actuator.
•
•
7.12.3
7.12.4
wc_tx000584gb.fm
If there is little or erratic movement, turn the
ignition switch OFF. Check that the jam nut (a)
at the bottom of the actuator cylinder is tight. If
the jam nut is loose, the actuator will have
erratic or no movement. Apply red Loctite or an
equivalent to the jam nut and tighten it. See section Removal and Installation of Electric Steering Actuators.
a
wc_gr003373
If the jam nut is tight, continue.
To test the actuator motor: Turn the ignition
switch OFF. Disconnect the wiring harness
from the right actuator motor M1. Use a
multimeter and check the resistance of the
actuator motor’s windings. Do so by probing
the connector (b). The resistance should be
0.2–1.0 Ohms.
•
If more than 1.0 Ohms is measured,
replace the right actuator.
•
If 0.2–1.0 Ohms is measured, continue.
The next two tests will check the control board.
First, with the ignition switch turned OFF,
check for battery voltage at the wiring harness
(c). There should be battery voltage between
the orange wire and ground and between the
black wire and ground.
•
If battery voltage is not measured, the
control board has failed; replace it.
•
If battery voltage is measured, continue.
86
b
wc_gr003374
c
wc_gr003375
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.
•
If your readings did not respond accordingly, the control board
has failed; replace it.
•
If your readings were OK, continue.
7.12.6
With the ignition switch OFF and the actuator motor still disconnected,
disconnect the wiring from the left actuator motor (M3),the left load pin
(L3), and the right load pin (L1).
7.12.7
Connect the wiring for the left actuator motor to the right actuator
motor, and the wiring for the left load pin to the right load pin.
LJS
L3
l3
L1
M3
m3
M1
P1
P2
C1
m1
wc_gr003377
l1
7.12.8
7.12.9
wc_tx000584gb.fm
Turn the ignition switch ON. Move the left joystick forward and
backward while watching the right actuator for movement. The right
actuator should move with the movements from the left joystick.
•
If the right actuator does not move, the right actuator has failed;
replace it.
•
If the right actuator moves, check the function of the right joystick.
After replacing any failed component, make sure to reposition the
wiring harness in the correct configuration and secure it with wire ties.
Turn the ignition switch ON and test the function of all three circuits:
right, left, and side.
87
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. Watch for movement of the side actuator
when the right joystick is moved to the full-left and full-right positions.
•
•
7.13.3
7.13.4
•
If more than 1.0 Ohms is measured,
replace the right actuator.
•
If 0.2–1.0 Ohms is measured, continue.
The next two tests will check the control board.
First, with the ignition switch turned OFF,
check for battery voltage at the wiring harness
(c). There should be battery voltage between
the orange wire and ground and between the
black wire and ground.
•
a
wc_gr003373
If the jam nut is tight, continue.
To test the actuator motor: Turn the ignition
switch OFF. Disconnect the wiring harness
from the side actuator motor M2. Use a
multimeter and check the resistance of the
actuator motor’s windings. Do so by probing
the connector (b). The resistance should be
0.2–1.0 Ohms.
•
wc_tx000584gb.fm
If there is little or erratic movement, turn the
ignition switch OFF. Check that the jam nut (a)
at the bottom of the actuator cylinder is tight. If
the jam nut is loose, the actuator will have
erratic or no movement. Apply red Loctite or an
equivalent to the jam nut and tighten. See section Removal and Installation of Electric Steering Actuators.
If battery voltage is not measured, check
the continuity of the wiring. Repair or
replace the wiring as needed.
If battery voltage is measured, continue.
88
b
wc_gr003374
c
wc_gr003375
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.
•
If your readings did not respond accordingly, the control board
has failed; replace it.
•
If your readings were OK, continue.
7.13.6
With the ignition switch OFF and the actuator motor still disconnected,
disconnect the wiring from the left actuator motor (M3), the left load pin
(L3), and the side load pin (L1).
7.13.7
Connect the wiring for the left actuator motor to the side actuator
motor, and the wiring for the left load pin to the side load pin.
LJS
L3
L1
M3
m1
M1
P1
P2
l2
C1
m2
L2
m3
M2
l3
wc_gr003379
7.13.8
7.13.9
wc_tx000584gb.fm
Turn the ignition switch ON. Move the left joystick forward and
backward while watching the side actuator for movement. The side
actuator should move with the movements from the left joystick.
•
If the side actuator does not move, the side actuator has failed;
replace it.
•
If the side actuator moves, check the function of the right joystick.
After replacing any failed component, make sure to reposition the
wiring harness in the correct configuration and secure it with wire ties.
Turn ignition switch ON and test the function of all three circuits: right,
left, and side.
89
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. Move the left joystick back and forth from
its full-forward to its full-reverse positions and watch for movement of
the left actuator.
•
•
7.14.3
7.14.4
wc_tx000584gb.fm
If there is little or erratic movement, turn the
ignition switch OFF. Check that the jam nut (a)
at the bottom of the actuator cylinder is tight. If
the jam nut is loose, the actuator will have
erratic or no movement. Apply red Loctite or an
equivalent to the jam nut and tighten it. See section Removal and Installation of Electric Steering Actuators.
a
wc_gr003373
If the jam nut is tight, continue.
To test the actuator motor: Turn the ignition
switch OFF. Disconnect the wiring harness
from the left actuator motor M3. Use a
multimeter and check the resistance of the
actuator motor’s windings. Do so by probing
the connector (b). The resistance should be
0.2–1.0 Ohms.
•
If more than 1.0 Ohms is measured,
replace the right actuator.
•
If 0.2–1.0 Ohms is measured, continue.
The next two tests will check the control board.
First, with the ignition switch turned OFF,
check for battery voltage at the wiring harness
(c). There should be battery voltage between
the orange wire and ground and between the
black wire and ground.
•
If battery voltage is not measured, the
control board has failed; replace it.
•
If battery voltage is measured, continue.
90
b
wc_gr003374
c
wc_gr003375
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.
•
If your readings did not respond accordingly, the control board
has failed; replace it.
•
If your readings were OK, continue.
7.14.6
With the ignition switch OFF and the actuator motor still disconnected,
disconnect the wiring from the right actuator motor (M1), the right load
pin (L1), and the left load pin (L3).
7.14.7
Connect the wiring for the right actuator motor to the left actuator
motor, and the wiring for the right load pin to the left load pin.
l1
L3
RJS
L1
M3
m1
M1
C1
P1
P2
l3
wc_gr003378
m3
7.14.8
7.14.9
wc_tx000584gb.fm
Turn the ignition switch ON. Move the right joystick forward and
backward while watching the left actuator for movement. The left
actuator should move with the movements from the right joystick.
•
If the left actuator does not move, the left actuator has failed;
replace it.
•
If the left actuator moves, check the function of the left joystick.
After replacing any failed component, make sure to reposition the
wiring harness in the correct configuration and secure it with wire ties.
Turn the ignition switch ON and test the function of all three circuits:
right, left, and side.
91
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. Then, check the continuity of
the wiring between pin 1 of the P2 connector and terminal A of the L1
connector. Also check pin 2 to terminal C, and pin 3 to terminal B.
•
If any of the wires is faulty, repair or replace the wiring.
•
If the wiring is OK, reconnect it and continue.
LJS
RJS
L3
L1
M3
M1
C1
P1
P2
6 5 4 3 2 1
7 8 9 10 11 12
1-A
2-C
3-B
A
B
C
F
E
D
wc_gr003376
wc_tx000584gb.fm
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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.
P2
1
wc_gr003384
7.15.4
Check if feedback voltage is being sent from the load pin to the control
board. To do so, leave the black lead connected to the common
ground, back probe the #2 terminal of the P2 connector with the red
lead, and turn the ignition switch ON. With the right joystick in the
center (neutral) position, the multimeter should read 2.5±0.2 VDC.
•
If 2.5±0.2 VDC is present, the system should be functioning. Any
problems are internal to the software of the control board. Consult Wacker Service.
•
If no voltage is present, the right load pin has failed; replace it.
2
P2
wc_gr003385
7.15.5
wc_tx000584gb.fm
After replacing any failed component, make sure to reposition the
wiring harness in the correct configuration and secure it with wire ties.
Turn the ignition switch ON and test the function of all three circuits:
right, left, and side.
93
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. Then, check the continuity of
the wiring between pin 1 of the P2 connector and terminal A of the L1
connector. Also check pin 2 to terminal C, and pin 3 to terminal B.
•
If any of the wires is faulty, repair or replace the wiring.
•
If the wiring is OK, reconnect it and continue.
LJS
RJS
L3
L1
M3
M1
C1
P1
P2
6 5 4 3 2 1
7 8 9 10 11 12
1-A
2-C
3-B
A
B
C
F
E
D
wc_gr003376
wc_tx000584gb.fm
94
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.
P2
1
wc_gr003384
7.16.4
Check if feedback voltage is being sent from the load pin to the control
board. To do so, leave the black lead connected to the common
ground, back probe the #2 terminal of the P2 connector with the red
lead, and turn the ignition switch ON. With the right joystick in the
center (neutral) position, the multimeter should read 2.5±0.2 VDC.
•
If 2.5±0.2 VDC is present, the system should be functioning. Any
problems are internal to the software of the control board. Consult Wacker Service.
•
If no voltage is present, the right load pin has failed; replace it.
2
P2
wc_gr003385
wc_tx000584gb.fm
95
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. Turn the ignition ON and check for voltage between the wire and
ground. There should be no voltage.
•
If voltage is measured, the load pin has failed; replace it.
•
If no voltage is measured, continue.
P2
a
3
wc_gr003386
7.16.6
With the wire to terminal #3 still disconnected, check the control board
for a voltage leak. Probe the connector at pin #3 with the red lead and
ground with the black lead.
•
If voltage is measured, the control board has failed; replace it.
•
If no voltage is measured, the system should be OK. Reconnect
terminal wire 3 to the connector.
3
P2
wc_gr003387
7.16.7
wc_tx000584gb.fm
After replacing any failed component, make sure to reposition the
wiring harness in the correct configuration and secure it with wire ties.
Turn the ignition switch ON and test the function of all three circuits:
right, left, and side.
96
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. Then, check the continuity of
the wiring between pin 4 of the P2 connector and terminal A of the L2
connector. Also check pin 5 to terminal C, and pin 6 to terminal B.
•
If any of the wires is faulty, repair or replace the wiring.
•
If the wiring is OK, reconnect it and continue.
LJS
RJS
L3
L1
M3
M1
C1
P1
P2
L2
M2
6 5 4 3 2 1
7 8 9 10 11 12
4-A
5-C
6-B
A
B
C
F
E
D
wc_gr003388
wc_tx000584gb.fm
97
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.
P2
4
wc_gr003389
7.17.4
Check if feedback voltage is being sent from the load pin to the control
board. To do so, leave the black lead connected to the common
ground, back probe the #5 terminal of the P2 connector with the red
lead, and turn the ignition switch ON. With the right joystick in the
center (neutral) position, the multimeter should read 2.5±0.2 VDC.
•
If 2.5±0.2 VDC is present, the system should be functioning. Any
problems are internal to the software of the control board. Consult Wacker Service.
•
If no voltage is present, the right load pin has failed; replace it.
P2
5
wc_gr003390
7.17.5
wc_tx000584gb.fm
After replacing any failed component, make sure to reposition the
wiring harness in the correct configuration and secure it with wire ties.
Turn the ignition switch ON and test the function of all three circuits:
right, left, and side.
98
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. Then, check the continuity of
the wiring between pin 4 of the P2 connector and terminal A of the L2
connector. Also check pin 5 to terminal C, and pin 6 to terminal B.
•
If any of the wires is faulty, repair or replace the wiring.
•
If the wiring is OK, reconnect it and continue.
LJS
RJS
L3
L1
M3
M1
C1
P1
P2
L2
M2
6 5 4 3 2 1
7 8 9 10 11 12
4-A
5-C
6-B
A
B
C
F
E
D
wc_gr003388
wc_tx000584gb.fm
99
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.
P2
4
wc_gr003389
7.18.4
Check if feedback voltage is being sent from the load pin to the control
board. To do so, leave the black lead connected to the common
ground, back probe the #5 terminal of the P2 connector with the red
lead, and turn the ignition switch ON. With the right joystick in the
center (neutral) position, the multimeter should read 2.5±0.2 VDC.
•
If 2.5±0.2 VDC is present, the system should be functioning. Any
problems are internal to the software of the control board. Consult Wacker Service.
•
If no voltage is present, the right load pin has failed; replace it.
P2
5
wc_gr003390
wc_tx000584gb.fm
100
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.
•
If voltage is measured, the load pin has failed; replace it.
•
If no voltage is measured, continue.
a
P2
6
wc_gr003391
7.18.6
With the wire to terminal #6 still disconnected, check the control board
for a voltage leak. Probe the connector at pin 6 with the red lead and
ground with the black lead.
•
If voltage is measured, the control board has failed; replace it.
•
If no voltage is measured, the system should be OK. Reconnect
the wire to terminal #6 to the connector.
P2
6
wc_gr003392
7.18.7
wc_tx000584gb.fm
After replacing any failed component, make sure to reposition the
wiring harness in the correct configuration and secure it with wire ties.
Turn the ignition switch ON and test the function of all three circuits:
right, left, and side.
101
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. Then, check the continuity of
the wiring between pin 7 of the P2 connector and terminal A of the L3
connector. Also check pin 8 to terminal C, and pin 9 to terminal B.
•
If any of the wires is faulty, repair or replace the wiring.
•
If the wiring is OK, reconnect it and continue.
LJS
RJS
L3
L1
M3
M1
C1
P1
P2
6 5 4 3 2 1
7 8 9 10 11 12
7-A
8-C
9-B
A
B
C
F
E
D
wc_gr003394
wc_tx000584gb.fm
102
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.
P2
7
wc_gr003395
7.19.4
Check if feedback voltage is being sent from the load pin to the control
board. To do so, leave the black lead connected to the common
ground, back probe the #8 terminal of the P2 connector with the red
lead, and turn the ignition switch ON. With the right joystick in the
center (neutral) position, the multimeter should read 2.5±0.2 VDC.
•
If 2.5±0.2 VDC is present, the system should be functioning. Any
problems are internal to the software of the control board. Consult Wacker Service.
•
If no voltage is present, the right load pin has failed; replace it.
P2
8
wc_gr003396
7.19.5
wc_tx000584gb.fm
After replacing any failed component, make sure to reposition the
wiring harness in the correct configuration and secure it with wire ties.
Turn the ignition switch ON and test the function of all three circuits:
right, left, and side.
103
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. Then, check the continuity of
the wiring between pin 7 of the P2 connector and terminal A of the L3
connector. Also check pin 8 to terminal C, and pin 9 to terminal B.
•
If any of the wires is faulty, repair or replace the wiring.
•
If the wiring is OK, reconnect it and continue.
LJS
RJS
L3
L1
M3
M1
C1
P1
P2
6 5 4 3 2 1
7 8 9 10 11 12
7-A
8-C
9-B
A
B
C
F
E
D
wc_gr003394
wc_tx000584gb.fm
104
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.
P2
7
wc_gr003395
7.20.4
Check if feedback voltage is being sent from the load pin to the control
board. To do so, leave the black lead connected to the common
ground, back probe the #8 terminal of the P2 connector with the red
lead, and turn the ignition switch ON. With the right joystick in the
center (neutral) position, the multimeter should read 2.5±0.2 VDC.
•
If 2.5±0.2 VDC is present, the system should be functioning. Any
problems are internal to the software of the control board. Consult Wacker Service.
•
If no voltage is present, the right load pin has failed; replace it.
P2
8
wc_gr003396
wc_tx000584gb.fm
105
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. Turn the ignition ON and check for voltage between the wire and
ground. There should be no voltage.
•
If voltage is measured, the load pin has failed; replace it.
•
If no voltage is measured, continue.
a
P2
9
wc_gr003397
7.20.6
With the wire to terminal #9 still disconnected, check the control board
for a voltage leak. Probe the connector at pin 9 with the red lead and
ground with the black lead.
•
If voltage is measured, the control board has failed; replace it.
•
If no voltage is measured, the system should be OK. Reconnect
the wire to terminal #9 of the connector.
P2
9
wc_gr003398
7.20.7
wc_tx000584gb.fm
After replacing any failed component, make sure to reposition the
wiring harness in the correct configuration and secure it with wire ties.
Turn the ignition switch ON and test the function of all three circuits:
right, left, and side.
106
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. Then, check the continuity
of the wiring between pins 2 through 6 of the P1 connector and the red
(R), white (W), gray (Gr), blue (L), and black (B) wires at the joystick
connector. See section Removal and Installation of Joysticks for
joystick disassembly.
•
If any of the wires is faulty, repair or replace the wiring.
•
If the wiring is OK, reconnect it and continue.
LJS
RJS
L3
L1
M3
M1
C1
P1
P2
B
R
W
Gr
L
6 5 4 3 2 1
7 8 9 10 11 12
wc_tx000584gb.fm
6-B
2-R
3 -W
4 - Gr
5-L
B
R
W
Gr
L
wc_gr003399
107
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
7.21.4
Check for feedback voltage (forward and reverse 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 #3 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.
3
P1
wc_gr003401
wc_tx000584gb.fm
108
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.
P1
4
wc_gr003402
7.21.6
Check the function of the control board ground pin 6. To do so, probe
terminal #2 of the P1 connector with the red lead of your multimeter
and terminal #6 with the black lead. You should measure 5.0±0.2
Volts.
•
If the proper voltage is not measured, the control board has
failed; replace it.
•
If the proper voltage is measured, the system should be functioning.
2
P1
6
wc_gr003403
wc_tx000584gb.fm
109
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. Then, check the continuity
of the wiring between pins 2 through 6 of the P1 connector and the red
(R), white (W), gray (Gr), blue (L), and black (B) wires at the joystick
connector. See section Removal and Installation of Joysticks for
joystick disassembly.
•
If any of the wires is faulty, repair or replace the wiring.
•
If the wiring is OK, reconnect it and continue.
LJS
RJS
L3
L1
M3
M1
C1
P1
P2
B
R
W
Gr
L
6 5 4 3 2 1
7 8 9 10 11 12
wc_tx000584gb.fm
6-B
2-R
3 -W
4 - Gr
5-L
B
R
W
Gr
L
wc_gr003399
110
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.
•
If the proper voltage is measured, continue.
P1
2
wc_gr003400
7.22.4
Check the feedback voltage at terminal #3 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 #3
terminal of the P1 connector with the red lead. With the right joystick in
the centered position, approximately 2.5 Volts should be measured.
•
If no voltage is measured, the right joystick has failed; replace it.
•
If the proper voltage is measured, continue.
3
P1
wc_gr003401
wc_tx000584gb.fm
111
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.
P1
4
wc_gr003402
7.22.6
Check the feedback voltage at terminal #5 of the 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 #5
terminal of the P1 connector with the red lead. With the right joystick in
the centered position, approximately 2.5V should be measured.
•
If the proper voltage is measured, the system should be functioning.
•
If the proper voltage is not measured, continue.
P1
5
wc_gr003404
wc_tx000584gb.fm
112
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. There should be no
voltage.
•
If voltage is measured, the joystick has failed; replace it.
•
If no voltage is measured, continue.
a
P1
6
wc_gr003405
7.22.8
With the black wire still disconnected, check the control board for a
voltage leak. Probe the #6 terminal of the P1 connector with the red
lead, and probe a common ground with the black lead.
•
If voltage is measured, the control board has failed; replace it.
•
If no voltage is measured, the system should be OK. Reconnect
the wire to terminal #6 of the connector.
P1
6
wc_gr003406
7.22.9
wc_tx000584gb.fm
After replacing any failed component, make sure to reposition the
wiring harness in the correct configuration and secure it with wire ties.
Turn the ignition switch ON and test the function of all three circuits:
right, left, and side.
113
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. Then, check the continuity
of the wiring between pins 7 through 10 of the P1 connector and the
red (R), gray (Gr), blue (L), and black (B) wires at the joystick
connector. See section Removal and Installation of Joysticks for
joystick disassembly.
•
If any of the wires is faulty, repair or replace the wiring.
•
If the wiring is OK, reconnect it and continue.
LJS
RJS
L3
L1
M3
M1
C1
P1
P2
B
R
(W)
Gr
L
6 5 4 3 2 1
7 8 9 10 11 12
wc_tx000584gb.fm
10 - B
7-R
8 - Gr
9-L
B
R
(W)
Gr
L
wc_gr003407
114
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.
P1
7
wc_gr003408
7.23.4
Check for feedback voltage at terminal #8 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 #8
terminal of the P1 connector with the red lead. With the left joystick in
the centered position, approximately 2.5 Volts should be measured.
•
If no voltage is measured, the left joystick has failed; replace it.
•
If proper voltage is measured, continue.
P1
8
wc_gr003409
wc_tx000584gb.fm
115
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. There should be no
voltage.
•
If voltage is measured, the joystick has failed; replace it.
•
If no voltage is measured, continue.
a
P1
10
wc_gr003411
7.23.6
With the black wire still disconnected, check the control board for a
voltage leak. Probe the #10 terminal of the P1 connector with the red
lead, and probe a common ground with the black lead.
•
If voltage is measured, the control board has failed; replace it.
•
If no voltage is measured, the system should be OK. Reconnect
the wire to terminal #6 of the connector.
P1
10
wc_gr003414
wc_tx000584gb.fm
116
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. Then, check the continuity
of the wiring between pins 7 through 10 of the P1 connector and the
red (R), gray (Gr), blue (L), and black (B) wires at the joystick
connector. See section Removal and Installation of Joysticks for
joystick disassembly.
•
If any of the wires is faulty, repair or replace the wiring.
•
If the wiring is OK, reconnect it and continue.
LJS
RJS
L3
L1
M3
M1
C1
P1
P2
B
R
(W)
Gr
L
6 5 4 3 2 1
7 8 9 10 11 12
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10 - B
7-R
8 - Gr
9-L
B
R
(W)
Gr
L
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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
7.24.4
Check for feedback voltage (forward and reverse 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 #8 terminal of the P1 connector. With the
left joystick in the centered position, 2.5±0.2 Volts should be
measured.
•
If no voltage is measured, the left joystick has failed; replace it.
•
If the proper voltage is measured, continue.
P1
8
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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. There should be no
voltage.
•
If voltage is measured, the joystick has failed; replace it.
•
If no voltage is measured, continue.
a
P1
10
wc_gr003411
7.24.6
With the black wire still disconnected, check the control board for a
voltage leak. Probe the #10 terminal of the P1 connector with the red
lead, and probe a common ground with the black lead.
•
If voltage is measured, the control board has failed; replace it.
•
If no voltage is measured, the system should be OK. Reconnect
the wire to terminal #10 of the connector.
P1
10
wc_gr003414
7.24.7
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After replacing any failed component, make sure to reposition the
wiring harness in the correct configuration and secure it with wire ties.
Turn the ignition switch ON and test the function of all three circuits:
right, left, and side.
119
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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.
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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. Recharge or replace the battery as needed.
The battery must be above 11VDC.
•
Test the alternator output. The alternator is rated at 65A. Replace
the alternator if needed.
121
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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.
7.27.6
Support the actuator and carefully remove the load pin (d). To prevent
damage to the actuator, secure it in the upright position.
Installation:
7.27.7
Rotate the load pin (d) so the alignment flat will engage the locking
plate (e). Align the mounting hole of the actuator with the frame and
carefully insert the load pin (d).
7.27.8
Install the retaining ring (c). Make sure the retaining ring is fully
engaged into the shaft groove.
7.27.9
Reconnect the load pin wiring connector (b).
7.27.10 Install the protective cover (a) on the rear actuator if it was removed.
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e
c
d
e
c
d
a
b
e
d
c
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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. To adjust the actuator length:
7.28.4
Loosen the locknut (d) and rotate the barrel (e) clockwise until it stops
retracting.
7.28.5
Rotate the barrel counterclockwise to achieve the dimension shown.
7.28.6
Install the load pin (b). See section Removal and Replacement of
Actuator Load Pins.
7.28.7
With the blades pitched flat and the trowel flat on the ground, screw the
rod end (f) in or out (while holding the barrel (e) so it does not rotate)
so that the rod end aligns with the mounting hole in the gearbox pivot
rod.
7.28.8
Apply Loctite 243 or an equivalent to the mounting screw (a) and
reinstall it through the rod end and into the gearbox pivot rod. Torque
the mounting screw to 77 ± 8 Nm (57 ± 6 ft.lbs.).
7.28.9
Apply Loctite 243 or an equivalent to the threads (g) above the locknut
(d) on the rod end. Using a band clamp or slip joint pliers to hold the
barrel, tighten the locknut to 41 ± 7 Nm (30 ± 5 ft.lbs.).
7.28.10 Turn the key switch to the ON position and test the actuator function(s).
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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
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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.
7.29.5
Lower the joystick (d) and the backing plate (e) from the housing.
Installation:
7.29.6
Position the backing plate (e) onto the joystick (d).
7.29.7
Insert the joystick into the housing from underneath the housing. Insert
the screws (c) with washers into the top of the housing and through the
backing plate. Install the locknuts and tighten.
7.29.8
Carefully connect the wiring harness (b) to the joystick.
7.29.9
Lower the joystick assembly onto the mount. Apply Loctite 243 or an
equivalent to the screws and install.
7.29.10 Reconnect the battery. Turn the key switch to the ON position and
check the function of the joystick.
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Steering and Pitch Control
c
a
e
d
B
R
(W)
Gr
L
b
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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.
7.30.5
Remove the mounting screws (d) holding the control board onto the
front panel and remove the control board.
Installation:
7.30.6
Inspect the control board. Make sure the insulating strips (e) are
attached to the back of the board. DO NOT INSTALL THE CONTROL
BOARD WITHOUT THE INSULATORS INSTALLED! The back of the
control board has battery-positive terminals on it that may short without
the insulating strip installed.
7.30.7
Place a drop of medium strength thread-lock compound onto the
mounting screws (d) for the control board and install it. Torque the
screws to 10 Nm (7 ft.lbs.).
7.30.8
Install the motor control wires onto the terminals of the control board.
Do not over-tighten the nuts when connecting the wires.
7.30.9
Install the protective cover (c).
7.30.10 Connect the gray connector (a) to the gray receptacle and the black
connector (b) to the black receptacle on the control board.
7.30.11 Reconnect the battery.
7.30.12 Turn the key switch ON and test all control board functions.
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Steering and Pitch Control
e
d
a
b
c
wc_gr003441
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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.
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.
Is the
ignition switch
OK?
Yes
Check continuity
of the wiring between
components.
Repair or replace
wiring as needed.
No
Replace the
ignition switch.
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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).
8.2.3
If the fuse is blown, replace it.
b
a
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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. Clean the terminal if necessary.
b
a
b
a
Vanguard
Honda
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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.
Table 1: Honda
Key position
Continuity between terminals
OFF
M–G, M–A, G–A
ON
R–B, R–A, B–A
START
S–B
Table 2: Vanguard
Key position
Continuity between terminals
OFF
M–G, M–X
ON
L–B, L–X, B–X
START
S–B, L–S, L–B
Honda
G
M
R
S
B
A
Vanguard
S
X
M
B
L
G
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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.
Is
fuel pump
operating?
No
Is 12V
measured?
No
Check function
of key switch.
Yes
Yes
See engine
repair manual.
Check for 12V* on R/B wire at
terminal 87 of operator present relay.
See Checking Operator Present Relay.
Is 12V
measured?
Yes
See Flowchart 2B
No
Check the wiring to and function
of throttle switch.
See Checking Throttle Switch.
Are
the wiring
and switch
OK?
* Battery voltage
approximately 12V
Repair wiring
and/or replace
throttle switch.
Yes
Replace operator
present relay.
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134
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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. If the fuel pump does not make any noise when
the key switch is in the ON position, it is not receiving power. The
problem is within the circuitry of the machine. Start troubleshooting by
checking the wiring to the fuel pump; continue with checking the 15A
fuse. If the fuel pump is receiving power and pumping fuel to the
engine, the problem is within the engine. See the engine
manufacturer’s repair manual. If the fuel pump is receiving power but
not pumping, the fuel pump has failed; replace it.
a
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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. If the fuse is blow; replace it.
a
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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.
8.8.2
Cut the wire ties that secure the operator presence relay.
8.8.3
Slide the connector down the terminals of the relay so that you can
probe the terminals with the lead of a multimeter.
8.8.4
Turn the ignition switch to the ON position.
8.8.5
Check for battery voltage between terminal 30 and ground.
8.8.6
•
If battery voltage is measured, the operator presence relay is
receiving power.
•
If battery voltage is not measured, check the continuity of the wiring between the operator presence relay and the ignition switch.
Repair or replace the wiring as needed.
Next, check if power is being switched through the operator presence
relay by checking for battery voltage between terminal 87 of the
operator presence relay and ground.
•
If battery voltage is measured, the operator presence relay is
functioning.
•
If battery voltage is not measured, the operator presence relay is
not functioning. Check the wiring to and function of the throttle
switch.
85
30
a
86
87a
87
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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). The throttle switch is a normally closed
switch and thus the circuit is completed when the throttle pedal is in the
idle position. As soon as the throttle pedal is pressed, the circuit is
broken and the operator presence relay will de-energize. However, if
the operator is in the seated position, the operator presence switch,
which is normally open, will close. The circuit for the operator presence
relay is now completed by the operator presence switch, which keeps
the operator presence relay energized, and allows the machine to
function. To check the function of the throttle switch, carry out the
following procedure:
8.9.1
Disconnect the wiring to the throttle switch (a).
8.9.2
Insert the leads of a multimeter into the wires coming from the throttle
switch.
8.9.3
Test the throttle switch for continuity when the throttle pedal is pressed
and when in the idle position (not pressed). There should be continuity
across the throttle switch when the throttle pedal is in the idle position
and no continuity when the throttle pedal is pressed.
8.9.4
8.9.5
wc_tx000585gb.fm
•
If the throttle switch functions accordingly, it is OK.
•
If the throttle switch does not function accordingly, it has failed;
replace it.
Test the operator presence switch (b) in the same manner. It is a
normally open switch and thus should only have continuity when the
operator is in the seated position.
•
If the operator presence switch functions accordingly, it is OK.
•
If the operator presence switch does not function accordingly, it
has failed; replace it.
If the throttle switch is OK, check the continuity of the wiring between
the throttle switch and the operator presence relay.
138
CRT Repair
Engine Troubleshooting and Replacement
a
b
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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.
* Battery voltage
approximately 12V
No
No
Repair wiring.
Yes
Check continuity of Br/W wire between
fuel relay and ignition module.
See Checking Ignition Module.
Is Br/W
wire OK?
No
Repair wiring.
Yes
Connect a jumper wire between
terminal 86 of the fuel relay and ground.
Turn the ignition to ON and check for
12V* to fuel pump.
Does
fuel pump
operate?
Yes
Troubleshoot
ignition module.
See engine repair
manual.
No
Replace fuel
relay.
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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.
8.11.3
Slide the connector down the terminals of the relay so that you can
probe the terminals with the lead of a multimeter.
8.11.4
Turn the ignition switch to the ON position.
8.11.5
Check for battery voltage between terminal 30 and ground.
8.11.6
•
If battery voltage is measured, the fuel relay is receiving power.
•
If battery voltage is not measured, check the continuity of the wiring between the operator presence relay and the fuel relay.
Repair or replace the wiring as needed.
Next, check if power is being switched through the fuel relay by
checking for battery voltage between terminal 87 of the fuel relay and
ground.
•
If battery voltage is measured, the fuel relay is functioning.
•
If battery voltage is not measured, the fuel relay is not functioning. Check the wiring to and function of the ignition module.
a
85
30
86
87a
87
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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).
8.12.3
Turn the ignition switch to the ON position.
8.12.4
Check for battery voltage between the P wire and ground.
8.12.5
•
If battery voltage is measured, the ignition module is receiving
power.
•
If battery voltage is not measured, check the continuity of the wiring between the operator presence relay and the ignition module.
Repair or replace the wiring as needed.
Next, check the continuity of the Br/W wire from the ignition module
(right side connector (c)) to terminal 86 of the fuel relay.
•
If the wire has no continuity, replace it.
•
If the wire has continuity, see the engine manufacturer’s repair
manual for troubleshooting the ignition module.
a
b
c
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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.
Is the
ignition switch
OK?
Yes
Check continuity
of the wiring between
components.
Repair or replace
wiring as needed.
No
Replace the
ignition switch.
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143
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.
8.14.6
Remove the screws that secure the cross brace (b) and remove the
cross brace.
8.14.7
Disconnect the wiring from the starter motor (c).
8.14.8
Cut the tie wraps, and disconnect the relays from the engine (d).
8.14.9
Remove the screw (e) and remove the ground wires from the engine.
8.14.10 Disconnect the throttle (f) and choke cable (g).
8.14.11 Disconnect the three wires of the oil pressure switch harness (h).
8.14.12 Remove the engine mounting bolts from underneath the machine.
When removing the engine mounting bolts also remove the battery
ground cable from the engine.
8.14.13 Using an appropriate lift or crane, lift the engine from the machine.
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Engine Troubleshooting and Replacement
a
b
a
b
e
d
c
g
h
f
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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).
8.15.5
Reinstall the screw (e) and the ground wires to the engine.
8.15.6
Reconnect the relays to the engine (d) and secure them with wire ties.
8.15.7
Reconnect the wiring to the starter motor (c).
8.15.8
Reinstall the cross brace (b).
8.15.9
Reconnect the fuel hose (a) to the fuel filter.
8.15.10 Open the fuel valve on the fuel tank.
8.15.11 Reinstall the drive belt. See section Belt Replacement.
8.15.12 Reconnect the battery.
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Engine Troubleshooting and Replacement
a
b
a
b
e
d
c
g
h
f
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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.
8.16.6
Unplug the wires from the ignition modules (b).
8.16.7
Unplug the oil pressure switch (c).
8.16.8
Unplug the anti-backfire solenoid (d).
8.16.9
Disconnect the wiring from the alternator (e).
8.16.10 Disconnect the wiring from the starter motor and the starter solenoid
(f).
8.16.11 Disconnect the wiring at connector (g).
8.16.12 Disconnect the fuel line (h) at the carburetor.
8.16.13 Disconnect the throttle (i) and the choke cable (j).
8.16.14 Unplug the temperature sender wire.
8.16.15 Cut tie wraps as needed.
8.16.16 Disconnect the ground cable from the engine (if not already done when
removing belt guard).
8.16.17 Remove the screws (k) on each side of the engine that secure the
engine to the cradle. Remove the radiator brackets (l) if need be.
Loosen the muffler (m) at the manifold if need be.
8.16.18 Using an appropriate lift or crane, lift the engine (n) from the machine.
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a
b
3
2
1
m
e
d
f
c
g
j
h
i
n
k
l
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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.
8.17.3
Connect the temperature sender wire.
8.17.4
Connect the throttle (i) and choke cable (j).
8.17.5
Connect the fuel line (h) at the carburetor.
8.17.6
Connect the wiring at the connector (g).
8.17.7
Connect the wiring to the starter motor and the starter solenoid (f).
8.17.8
Connect the wiring to the alternator (e).
8.17.9
Connect the anti-backfire solenoid (d).
8.17.10 Connect the oil pressure switch (c).
8.17.11 Connect the wires to the ignition modules (b).
8.17.12 Secure all the wiring with tie wraps as needed.
8.17.13 Secure the cross brace (a).
8.17.14 Install the drive belt. See section Belt Replacement.
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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
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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
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CRT Repair
Engine Troubleshooting and Replacement
Honda Motor
Ref.
Description
Ref.
Description
1
Spark plug (right)
16
Relay—safety system
2
Coil-ignition (right)
17
Fuse 15A—light circuit
3
Engine stop diode
18
Light switch
4
Regulator/rectifier
19
Left front light
-
---
20
Left rear light
6
Spark plug (left)
21
Right front light
7
Coil-ignition (left)
22
Right rear light
8
Charging coil—20 Amp
23
Fuse 20A—accessory outlet
9
Battery
24
Accessory outlet
10
Starter motor
25
Fuse 5A—spray system
11
Fuel cut-off solenoid
26
Spray pump switch
12
Key switch
27
Spray pump motor
13
Starter relay
28
Oil pressure indicator light
14
Operator presence switch
(normally open)
29
Hour meter
15
Throttle sense switch
(normally closed)
30
Oil pressure switch (dual circuit)
Wire Colors
B
Black
R
Red
Y
Yellow
Or
Orange
G
Green
T
Tan
Br
Brown
Pr
Purple
L
Blue
V
Violet
Cl
Clear
Sh
Shield
P
Pink
W
White
Gr
Gray
LL
Light blue
wc_tx000585gb.fm
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Engine Troubleshooting and Replacement
CRT Repair
8.19 Wiring Schematic-Vanguard Engine (manual steer)
wc_tx000585gb.fm
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CRT Repair
Engine Troubleshooting and Replacement
Vanguard Motor (manual steer)
Ref.
Description
Ref.
Description
1
Work lights
18
Fuse 20A
2
Light switch
19
Fuse 5A
3
DC accessory outlet
20
Starter
4
Water pump
21
Key switch
5
Sprayer pump switch
22
Fuse 50A
6
Seat switch (normally open)
23
Battery
7
Operator presence relay
24
Hour meter
8
Throttle pedal
25
Alternator
9
Throttle switch (normally closed)
26
Charging light
10
Fuel pump relay
27
Overheating warning light
11
Fuel pump
28
Oil pressure indicator light
12
Crankshaft pulley
29
Oil level switch
13
Trigger coil
30
Water temperature switch
14
Ignition module
31
Ignition coils
15
Carburetor
32
(not used)
16
Solenoid
33
(not used)
17
Fuse 15A
Wire Colors
B
Black
R
Red
Y
Yellow
Or
Orange
G
Green
T
Tan
Br
Brown
Pr
Purple
L
Blue
V
Violet
Cl
Clear
Sh
Shield
P
Pink
W
White
Gr
Gray
LL
Light blue
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Engine Troubleshooting and Replacement
CRT Repair
8.20 Wiring Schematic-Vanguard Engine (electric steer)
wc_tx000585gb.fm
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CRT Repair
Engine Troubleshooting and Replacement
Vanguard Motor (electric steer)
Ref.
Description
Ref.
Description
1
Work lights
22
Fuse 50A
2
Light switch
23
Battery
3
DC accessory outlet
24
Hour meter
4
Water pump
25
Alternator
5
Fuse 70A
26
Charging light
6
Seat switch (normally open)
27
Overheating warning light
7
Operator presence relay
28
Oil pressure indicator light
8
Throttle pedal
29
Oil level switch
9
Throttle switch (normally closed)
30
Water temperature switch
10
Fuel pump relay
31
Ignition coils
11
Fuel pump
32
Left joystick
12
Crankshaft pulley
33
Right joystick
13
Trigger coil
34
Right load pin
14
Ignition module
35
Side load pin
15
Carburetor
36
Left load pin
16
Solenoid
37
Status OK indicator light (green)
17
Fuse 15A
38
Status error indicator light (red)
18
Fuse 20A
39
Electronic control module
19
Fuse 5A
40
Right actuator
20
Starter
41
Side actuator
21
Key switch
42
Left actuator
Wire Colors
B
Black
R
Red
Y
Yellow
Or
Orange
G
Green
T
Tan
Br
Brown
Pr
Purple
L
Blue
V
Violet
Cl
Clear
Sh
Shield
P
Pink
W
White
Gr
Gray
LL
Light blue
wc_tx000585gb.fm
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Engine Troubleshooting and Replacement
Vanguard (electric steer)
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CRT Repair
CRT Repair
Engine Troubleshooting and Replacement
Vanguard Motor (electric steer)
Ref.
Description
Ref.
Description
1
Work lights
22
Fuse 50A
2
Light switch
23
Battery
3
DC accessory outlet
24
Hour meter
4
Water pump
25
Alternator
5
Fuse 70A
26
Charging light
6
Seat switch (normally open)
27
Overheating warning light
7
Operator presence relay
28
Oil pressure indicator light
8
Throttle pedal
29
Oil level switch
9
Throttle switch (normally closed)
30
Water temperature switch
10
Fuel pump relay
31
Ignition coils
11
Fuel pump
32
Left joystick
12
Crankshaft pulley
33
Right joystick
13
Trigger coil
34
Right load pin
14
Ignition module
35
Side load pin
15
Carburetor
36
Left load pin
16
Solenoid
37
Status OK indicator light (green)
17
Fuse 15A
38
Status error indicator light (red)
18
Fuse 20A
39
Electronic control module
19
Fuse 5A
40
Right actuator
20
Starter
41
Side actuator
21
Key switch
42
Left actuator
Wire Colors
B
Black
R
Red
Y
Yellow
Or
Orange
G
Green
T
Tan
Br
Brown
Pr
Purple
L
Blue
V
Violet
Cl
Clear
Sh
Shield
P
Pink
W
White
Gr
Gray
LL
Light blue
wc_tx000585gb.fm
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Engine Troubleshooting and Replacement
Notes:
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CRT Repair
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.
TYPE
( ) = Europe
Loctite 222
Hernon 420
Omnifit 1150 (50M)
COLOR USAGE
Purple Low strength, for locking threads smaller
than 6 mm (1/4”).
Hand tool removable.
Temp. range: -54 to 149°C (-65 to 300°F)
Blue
Medium strength, for locking threads
Loctite 243
Hernon 423
larger than 6 mm (1/4”).
Omnifit 1350 (100M)
Hand tool removable.
Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 271/277
Red
High strength, for all threads up to 25 mm
Hernon 427
(1”).
Omnifit 1550 (220M)
Heat parts before disassembly.
Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 290
Green Medium to high strength, for locking
Hernon 431
preassembled threads and for sealing
Omnifit 1710 (230LL)
weld porosity (wicking).
Gaps up to 0.13 mm (0.005”)
Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 609
Green Medium strength retaining compound for
Hernon 822
slip or press fit of shafts, bearings, gears,
Omnifit 1730 (230L)
pulleys, etc.
Gaps up to 0.13 mm (0.005”)
Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 545
Brown Hydraulic sealant
Hernon 947
Temp. range: -54 to 149°C (-65 to 300°F)
Omnifit 1150 (50M)
Loctite 592
White
Pipe sealant with Teflon for moderate
Hernon 920
pressures.
Omnifit 790
Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 515
Purple Form-in-place gasket for flexible joints.
Hernon 910
Fills gaps up to 1.3 mm (0.05”)
Omnifit 10
Temp. range: -54 to 149°C (-65 to 300°F)
PART NO. –
SIZE
73287 - 10 ml
29311 - .5 ml
17380 - 50 ml
29312 - .5 ml
26685 - 10 ml
73285 - 50 ml
28824 - .5 ml
25316 - 10 ml
29314 - .5 ml
79356 - 50 ml
26695 - 6 ml
73289 - 50 ml
70735 - 50 ml
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. The sealants
listed are recommended for use on Wacker equipment.
TYPE
( ) = Europe
COLOR USAGE
Loctite 496
Clear
Instant adhesive for bonding rubber, metal
Hernon 110
and plastics; general purpose.
Omnifit Sicomet 7000
For gaps up to 0.15 mm (0.006”)
Read caution instructions before using.
Temp. range: -54 to 82°C (-65 to 180°F)
Loctite Primer T
Aerosol Fast curing primer for threadlocking,
Hernon Primer 10
Spray
retaining and sealing compounds. Must
Omnifit VC Activator
be used with stainless steel hardware.
Recommended for use with gasket
sealants.
PART NO. –
SIZE
52676 - 1oz.
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
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
8.5
6
10
7
8
5/16
4
–
M6
10
7
14
10
17
13
10
–
5
–
M8
25
18
35
26
41
30
13
1/2
6
–
M10
49
36
69
51
83
61
17
11/16
8
–
M12
86
63
120
88
145
107
19
3/4
10
–
M14
135
99
190
140
230
169
22
7/8
12
–
M16
210
155
295
217
355
262
24
15/16
14
–
M18
290
214
405
298
485
357
27
1-1/16
14
–
M20
410
302
580
427
690
508
30
1-1/4
17
–
1 ft.lb. = 1.357 Nm
* = in.lb.
1 inch = 25.4 mm
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
8.1
6
12
9
16
12
–
7/16
–
3/32
5/16
18
13
26
19
33
24
13
1/2
–
1/4
3/8
31
23
45
33
58
43
–
9/16
–
5/16
7/16
50
37
71
52
94
69
16
5/8
–
3/8
1/2
77
57
109
80
142
105
19
3/4
–
3/8
9/16
111
82
156
115
214
158
–
13/16
–
–
5/8
152
112
216
159
265
195
24
15/16
–
1/2
3/4
271
200
383
282
479
353
–
1-1/8
–
5/8
1 ft.lb. = 1.357 Nm
* = in.lb.
1 inch = 25.4 mm
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. +852 2406 60 32 · Fax: +852 2406 60 21
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