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Summary of Contents for Carter CT12
- Page 1 CT12 MINI CRAWLER EXCAVATOR OPERATION & MAINTENANCE MANUAL SHAN DONG CARTER HEAVY INDUSTRY MACHINERY CO., LTD Add: Economic Development Zone, Linshu County, Shandong Province, 276715, China 86-539-7190561 Tel: +...
- Page 2 Preface Chapter I Usage Features and Performance Parameters of Carter 1.2T Excavators Section I Usage and features Section II Main performance parameters Chapter II Basic Structures and Work principle of Carter 1.2T Excavators Section I Overview Section II Work principle...
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Page 3: Section I Usage And Features
Excavators Section I Usage and features Carter 1.2T Excavators are provided with excavating, crushing, ditch cleaning, drilling and bulldozing, with their attachments quick hitched and thus its utilization up greatly. In addition, they are easy to operate and transport and flexible to work at narrow site. - Page 4 Quick hitch Narrow bucket Log grab Mechanical thumb Auger Ripper Rake...
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Page 5: Section Ii Main Performance Parameters
Section II Main performance parameters... -
Page 6: Appearance Parameters
Appearance parameters CT12 Overall dimensions Unit:mm A Wheel track 1296 B Overall length of track C Ground clearance of platform D Tail turning radius 850/1050 E Chassis width(scalable) F Crawler width G Crawler height 3053 H Transportation length 2588 I Overall height（Driving shed top）... - Page 7 1-1. Mounted on the rotary table are the regular full-swing type hydraulic excavators, main components of drive system, swing mechanism and auxiliary devices, which are referred to as upper rotary. Therefore, a Carter 1.2T excavator is divided into work equipment, upper rotary and traveling mechanism.
- Page 8 Section II Work principle of excavators Diesel engine changes the chemical energy of diesel into mechanical energy that is then altered with hydraulic gear pump to hydraulic energy that is distributed to each actuating element (such as hydraulic cylinder, swing motor and traveling motor). After that, each actuating element transform the hydraulic energy back to mechanical energy, driving the work equipment and running the complete machine.
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Page 9: Section Iii Basic Structure Of Carter 1.2T Excavators Mechanical System
3.1 Slewing support Carter 1.2T excavator has its rotary table supported with a rolling bearing, realizing the swinging of upper rotary. 3.2 Rotary drive Carter 1.2T excavator adopts the direct drive type. Namely, the output shaft of low-speed high-torque hydraulic motor is mounted with a driving pinion which meshes with the slewing gear ring. - Page 10 4.3 Bucket 4.3.1 Basic requirements The longitudinal profile of bucket meets the law of motion of various materials inside of bucket, facilitating the material flow and minimizing the loading resistance and thus fulfilling the bucket. Bucket teeth are mounted to increase the linear specific pressure of bucket onto material, with unit cutting resistance relatively low and easing to cut in and break soil.
- Page 12 Hydraulic system structure of Carter 1.2T excavators I. Rotary motor II. Main pump...
- Page 13 Ⅲ.Traveling motor Disc Valve Motors---R6K series -310 Flow Speed Pressure Torque (L/min) (RPM) (Mpa) (Nm) Displacement Continuous Intermittent Continuous Intermittent Continuous Intermittent Continuous Intermittent (cc/r) work work work work work work work work 1225...
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Page 14: Section Iv Schematics Of Main Valve
Section IV Schematics of main valve Stretch Rotating Side swing Traveling Traveling Fracture Boom Front shovel Bucket... -
Page 15: Section V. Electrical System Diagram
Section V. Electrical system diagram... -
Page 16: Section Ii Preparation For Work
Chapter III Service Technologies of Carter 1.2T Excavators Being of high temperature and pressure, the Carter 1.2T excavator could have the hydraulic oil temperature as high as 85℃, the engine silencer temperature as high as 700℃ and pressure as high as 18MPa. Therefore, the operators should be specially trained to obtain the proper certificates and to be familiar with the contents in this manual before the operations. - Page 17 When hydraulic oil is less than 25℃, it is needed to preheat the machine before any work; otherwise machine may not respond or react very quickly, leading to severe accident. Therefore it is needed to preheat machine if it is cold: ①.
- Page 18 2.2 Basic excavation 2.2.1 Before excavation, the arm cylinder should have angle with the arm as 90°, bucket with ground to be excavated as 30°. Only in such case, can each cylinder have the max. excavating force. It is suitable for relatively hard soil, so as to decrease the excavating resistance.
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Page 19: Section Iv Operational Precautions
Section IV Operational Precautions Prohibitions and precautions for hydraulic excavators Avoid the landsliding and the stone falling. Avoid any striking of work equipment. Avoid the bucket from colliding with other vehicle body, the loaded bucket crossing over other vehicle cab or persons. -
Page 20: Section I Daily Inspection And Maintenance
Chapter Ⅳ Maintenance of Carter 1.2T Excavators Section I Daily inspection and maintenance Interval (h) Item Quantity Remark everyday Check the engine oil level in sump ★ Check the hydraulic oil level in hydraulic oil tank ★ Check the fuel level in tank ★... - Page 21 Section II Periods of overhaul, medium and minor repair Interval (h) Maintenance items Remark 1000 1500 2000 2500 4000 Greasing of slewing bearing ★ Greasing of slewing bearing ★ gears Change the engine oil ● ★ Change the engine oil filter ●...
- Page 22 Technical maintenance A、 Grease Interval (h) Parts Quantity 1000 2000 Pivot at base of boom Pivot at base of Stick and bulldozer Lubrication of ★ Pivots of bucket and work equipment connecting rod pins Cylinder connection ★ 2.Lubrication of slewing bearing ★...
- Page 23 ● Others Pivot of Bulldozer cylinder; pivot of Boom cylinder and stick cylinder; pivot at base of bucket cylinder and deflection head cylinder pivot Slewing bearing - every 100h 2.1 Park machine on the flat ground. 2.2 Lower the bucket onto ground. 2.3 Idle engine at low speed for 5min.
- Page 24 3.1 Park machine on the flat ground. 3.2 Lower the bucket onto ground. 3.3 Idle engine at low speed for 5min. 3.4 Turn the ignition switch to OFF and then take off the key. 3.5 The grease has to be stored on the top of external meshing gear of slewing bearing, free of any pollution. Add approximate 0.5kg of grease if needed.
- Page 25 Inspection of engine oil level ―――-each day Change of engine oil ―――every 250 h Change the engine oil filter ―――every 250 h Start up engine to preheat up engine oil properly. Park the vehicle on the flat ground. Lower the bucket onto the ground. Idle engine at low speed for 5min.
- Page 26 Ⅰ、Inspection and maintenance of hydraulic system Caution: in work, the hydraulic system may become very hot. Please cool the machine down before inspection or maintenance! Before maintenance of hydraulic system, make sure the machine stands on flat and solid ground. Lower the bucket onto ground and shut down engine.
- Page 27 Ⅱ、 Inspection of hydraulic oil level --- each day Important: With no hydraulic oil, never start up engine! Park machine on the flat ground. Completely retract the arm cylinder and extend out the bucket cylinder, so as to locate the machine. Lower the bucket onto the ground.
- Page 28 III. Change the hydraulic oil ---1000 h Replace the hydraulic oil suction filter element---- every 500 h Caution: do not do so until the hydraulic oil cools down as it may be very hot. Park machine on the flat ground. Completely retract the arm cylinder and extend out the bucket cylinder, so as to locate the machine.
- Page 29 Ⅳ、 Inspection of hose and pipeline --- Each day --- Every 250h Caution: any sprayed fluid could penetrate your skin, leading to personal casualty! Therefore, use a paperboard to check for leakage. In addition, care must be taken to keep your hands and body away from pressure oil. In case of accident, please immediately go to doctor with trauma experience.
- Page 30 Please use the genuine Carter excavator parts Interval (h) Check points Abnormal Measures Hose surface Leakage 1 Replace it Leakage 2 Every day Hose end Replace it Connector body Leakage 3 Tighten or replace the hose or O-ring Hose surface...
- Page 31 D、Fuel system The division of ct12 product series is based on different selected engines, mainly involving YANMAR 3TNV70- SSY / 3TNV74F diesel engine, Kubota D722-E48-CBH diesel engine and YOUPU diesel engine. Finally, a brief introduction of various models of diesel engines is attached.
- Page 32 Drain steps: Caution: the drain plug is designed to be counter - thread type and should be turned with hands, instead of vise and wrench for protection of thread 1.Position an approved container under the fuel filter / water separator ⑴ to collect the contaminants. 2.Close the fuel cock (2) 3.Loosen the drain cock (4) at the bottom of the fuel filter / water separator.
- Page 33 Replace the battery There is a 12V battery with one negative pole (-) grounded. If battery cannot be charged or store any electricity, replace the battery with same model. Replace the fuse. If the electrical device does not work, please firstly check the fuse. Important: please install the fuse with correct amperage, so as to prevent against burning of electrical system due to overloading! Others...
- Page 34 Caution: care must be taken to avoid the metal scrap from flying out, leading to personal injury. Wear the goggles or the safe glasses or safe devices suitable for operations! Change the bucket Caution: while hitting out or into the connecting pin, care must be taken to prevent against any personal injury due to out-flied metal scrap.
- Page 35 Check the bolts and nuts for tightening torque — every 250 h (Originally for every day) Check the tightness for every day and then every 250 h. Tighten it to the set torque if needed. Replace it with bolts and nuts with same or higher grade. Important: please use the torque wrench to check the torques of bolts and nuts! Metric bolts and nuts Thread dimensions...
- Page 36 Maintenance under the special cases Operational conditions Precautions for maintenance Before operation, check all the drain plugs are tightened up. After operation, clean machine and check bolts and nuts for break, damage, Moor land, rainy or snowy looseness or loss. Lubricate all parts to be lubricated on time. Before operation, check all the drain plugs are tightened up.
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Page 37: Section I General
Chapter Ⅴ Troubleshooting Section I General To ensure excellent performance of Carter excavator, all components and parts are of high quality. Machine’s performance and service life are determined not only by manufacturing quality and assembling quality, but also maintenance quality. - Page 38 Symptom Possible causes How to solve The main pump supplying fuel to unilateral Change crawler is damaged. The main valve rod is stuck and the spring is Repair or change broken The unilateral crawler fails to move Traveling motor is damaged Change The upper and lower chambers of swivel Change the oil seal or clean the...
- Page 39 Symptom Possible causes How to solve The sealing component of central rotation Change the sealing component connector is aged and damaged. The left and right crawlers are of different Adjust tightening. Boom (bucket rod and Main valve core is stuck or valve rod spring Repair or change bucket) move to one breaks.
- Page 40 Symptom Possible causes How to solve Rotary valve rod on main valve is stuck. Repair Rotary motor is damaged Repair or change other abnormalities) The rotation support is damaged. Change The right and left rotation of multiway valve Adjust Indifferent left and right is of different overloaded pressure rotation speed (no other Rotation valve rod of multiway valve is...
- Page 41 SectionⅣ Troubleshooting of electrical control system Fault codes of electrical control system of excavator ⑴ The engine fails to start ⑵ The engine flames out during operation ⑶ The engine fails to flame out ⑷ Automatic slow-down does not work ⑸...
- Page 42 Possible causes Standard value in regular condition and reference value of fault diagnosis Between 105 and Unlocked 1MΩ Locked Below 1Ω ★Turn the start switch of engine to OFF as preparation and keep it at OFF during diagnosis. If all PS, GND, signals and engine start input are correct while engine start output is abnormal, the engine starter relay fails.
- Page 43 Section V Troubleshooting of diesel engine Symptoms of failed startup of engine: When starting the engine, the starter drives the engine but the engine fails to be started. Possible causes: (1) Low battery; (2) Battery terminal is rusted or loose; (3) Battery earth wire is rusted or loose or poor GND of engine;...
- Page 44 (5) Inspect and repair the engine. Only when the engine works well can the start-up fail never or seldom happen. Check if it is hard to start the engine Engine symptom: (1) Starter runs at correct rpm and drives the engine; however, it is hard to start the engine. (2) It is hard to start the engine when it is cold.
- Page 45 (4) Start circuit is disabled. (5) Electromagnetic relay armature is adherent; (6) Starter fault (7) Driving gear of starter is stuck by engine flywheel gear ring; (8) Driving gear of starter adheres to the bearing. (9) The starter fails to drive the engine; (10) Engine fault;...
- Page 46 Attachment Ⅰ: 3TNV70-SSY Engine Model 3TNV70-SSY Type 4 cycle, in-line, Water-cooled Diesel engine Combustion System Indirect injecction Aspiration Natural No. of Cylinders Bore × Stroke 2.756 x 2.913 in. (70 × 74 mm) Displacement 52.105 cu in. (0.854 L) RPM(min-1) 1500 1800 2000...
- Page 47 Attachment Ⅲ: D722-E4B-CBH-1 D722-E4B-CBH-1 Engine Model Type 4 cycle, in-line, Water-cooled Diesel engine Combustion System Indirect injecction Aspiration Natural No. of Cylinders Bore × Stroke (67 × 68 mm) Displacement (0.719 L) RPM (min-1) 1500 1700 1900 2100 2300 2600 10.2 Rated Output 8.57...