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Summary of Contents for Carter CT08
- Page 1 CT08 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 86-539-7190561 Tel: + Fax: +...
- Page 2 Preface Chapter I Usage Features and Performance Parameters of Carter 0.8T Excavators Section I Usage and features Section II Main performance parameters Chapter II Basic Structures and Work principle of Carter 0.8T Excavators Section I Overview Section II Work principle...
- Page 3 Excavators Section I Usage and features Carter 0.8T 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...
- Page 5 Section II Main performance parameters...
- Page 6 Overall dimensions Unit: mm A Wheel track 1233 B Overall length of track C Ground clearance of platform D Ground clearance of platform tail E Chassis width F Crawler width H Crawler height 2876 I Transportation length 1495 J Overall height（Driving shed top） Work range Unit: mm 2992...
- 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 0.8T 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).
- Page 9 The hydraulic excavator could have multiple work equipment, up to dozens of varieties, with backhoe and ripper most popular. Carter 0.8T excavator has the boom, arm and bucket articulated with each other, as shown in figure and swing around their articulated points respectively with aid of the hydraulic cylinder, finishing the excavating, lifting and unloading.
- Page 10 5.2 Bucket 5.2.1 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 0.8T excavators I. Rotary motor II. Main pump...
- Page 13 Ⅲ.Traveling motor Disc Valve Motors---6000 series -005 and -006 Drive, Main Geroler Screw, Cap Screw, Cap Displacement Item No.5--Part No Item No.6--Part No Item No.6--Part No Item No.6--Part No /r(in /Length /Width /Length /Length Part No mm(inch) Part No mm(inch) Part No mm(inch) Part No...
- Page 14 Seal package Code Name (reference dimensions mm) Quantity Dust cover (OD 50.9) Copper sheet (OD 60.45) Seal ring of output shaft (OD 63.56) O-ring (ID92.87，Shore hardness70) End seal ring (ID 45.72) O-ring (ID 6.07) O-ring (ID 94.97) O-ring (ID 11.2) Front-type seal ring (ID 62.23) Front-type seal ring (ID 35.82) O-ring (ID 92.33，Shore hardness 90)
- Page 15 Section IV Schematics of main valve Reserved rotating Traveling Front shovel Traveling Boom Bucket...
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Page 16: Section V. Electrical System Diagram
Section V. Electrical system diagram... -
Page 17: Section Ii Preparation For Work
Chapter III Service Technologies of Carter 0.8T Excavators Being of high temperature and pressure, the Carter 0.8T excavator could have the hydraulic oil temperature as high as 85℃, the engine silencer temperature as high as 700℃ and pressure as high as 16-18MPa. 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 18 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 19 2.2 Basic excavation 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 20: 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 21 Chapter VI Maintenance of Carter 0.8T Excavators Section I Daily inspection and maintenance Interval (h) Item Quantity Remark ★ Check the engine oil level in sump ★ Check the hydraulic oil level in hydraulic oil tank ★ Check the fuel level in tank Check the oil-water separator to completely drain ★...
- Page 22 Section II Periods of overhaul, medium and minor repair Interval (h) Remark 1000 100 250 1500 2000 2500 4000 Item Greasing of slewing ★ bearing Greasing of slewing ★ bearing gears ● ▲ Change the engine oil Change the hydraulic △...
- Page 23 Technical maintenance A Grease Interval (h) Parts Quantity 1000 2000 Pivot at base of boom 1. Lubrication Pivot at base of boom ★ of work cylinder equipment Pivots of bucket and pins connecting rod ★ Others: ★ 2. Lubrication of slewing bearing 3.
- Page 24 ● Others Pivot between boom and arm; pivot of arm cylinder plunger; pivot at base of bucket cylinder. Slewing bearing - every 250h Park machine on the flat ground. Lower the bucket onto ground. Idle engine at low speed for 5min. Turn the ignition switch to OFF and then take off the key.
- Page 25 B. Engine oil Interval (h) Parts Quantity 1000 2000 ● ▲ Engine oil ● ▲ Engine oil filter According to the temperature range during the interval, select the viscosity of oil listed in the table below: Recommended engine oil brand: 15W—40 engine oil...
- Page 26 Inspection of engine oil level ―――-each day Change of engine oil ―――every 100 h Change the engine oil filter ―――every 100 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 27 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 28 I. 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 29 III. Change the hydraulic oil ---2000 h Replace the hydraulic oil suction filter element ----every 1000 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 30 23. Check the hydraulic oil level in hydraulic oil tank and add it if needed. . V. Inspection of hose and pipeline --- Each day ---every 250 h Caution: any sprayed fluid could penetrate your skin, leading to personal casualty! Therefore, use a paperboard to check for leakage.
- Page 31 Please use the genuine Carter excavator parts Interval (h) Check points Abnormal Measures Replace it Hose surface Leakage 1 Replace it Every day Hose end Leakage 2 Tighten or replace the Connector body Leakage 3 hose or O-ring Crack 4...
- Page 32 capacity of fuel tank: 8.6L Fuel system Interval (h) Parts Quantity 1000 2000 Drain dirt out of collector of fuel ★ tank ★ Check the oil-water separator ★ Change the oil-water separator ★ ★ Leakage Check the fuel hose. ★ ★...
- Page 33 Manually loosen the drain plug at bottom of oil- water separator. After the draining, manually tighten the drain to ensure no leakage of oil or air. Caution: after the draining, make sure air is drained out of fuel system to make sure the engine could start up normally.
- Page 34 Note: ★ Maintenance interval under normal conditions Maintenance needed at the first inspection Contact dealers or Carter. Check the bucket teeth --- each day Check if the bucket teeth is worn or loosened. Worn beyond the service limit, the bucket teeth may be replaced.
- Page 35 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 36 Check the bolts and nuts for tightening torque ……every 250 h (initially at 50 h) Check the tightness at initial 50h 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 37 Maintenance under the special cases Operational conditions Precautions for maintenance Before operation, check all the drain plugs are tightened up. Moor land, rainy or snowy After operation, clean machine and check bolts and nuts for break, damage, looseness or loss. Lubricate all parts to be lubricated on time. Before operation, check all the drain plugs are tightened up.
- Page 38 Chapter XII 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 39 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 40 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 bucket) move to one Repair or change breaks.
- Page 41 Symptom Possible causes How to solve other abnormalities) Rotary valve rod on main valve is stuck. Repair Rotary motor is damaged Repair or change The rotation support is damaged. Change The right and left rotation of multiway valve Indifferent left and right Adjust is of different overloaded pressure rotation speed (no other...
- Page 42 Section IV Troubleshooting of electrical control system Fault codes of electrical control system of excavator The engine fails to start The engine flames out during operation The engine fails to flame out Automatic slow-down does not work Slewing and traveling of all working devices. Principle diagram 1.
- Page 43 Possible causes Standard value in regular condition and reference value of fault diagnosis 1MΩ Between 105 and Unlocked Below 1Ω Locked ★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 44 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 45 (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 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 46 (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;...
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Page 47: Safety Belt
Safety belt Make sure that the safety belt is not twisted and that the end of the safety belt is inserted into the buckle. Gently pull the seat belt to make sure that the buckle is fastened. 2． Adjust the safety belt so that it is just and comfortable on the waist of the operator. 3．... -
Page 48: Safety Lock
Safety lock Caution！ Keep in mind that the safety switch should be in the locked state after the completion of the excavator operation, so as to avoid accidentally touching the handle, the machine will move, which may cause serious injury 。 Safety lock switch Lock position (when the safety lock switch is in the lock position, the handle can be operated) Unlocking position (when the safety lock switch is in the unlocking position, the handle cannot be operated)