CONTENTS · 1.1.1 RECOGNIZE SAFETY LABEL (a) This is the label of “safety”. ... Please follow...

CONTENTS

FOREWORD ..................................................................................................................................................... I

BEFORE SERVICING THIS MACHINE .................................................................................................... II DECLARATION OF CONFORMITY ....................................................................................................... III TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.......................................................................... IV

1 SAFETY ......................................................................................................................................................... 1

1.1 SAFETY INFORMATION ..................................................................................................................... 1 1.1.1 RECOGNIZE SAFETY LABEL ..................................................................................................... 1 1.1.2 UNDERSTAND SIGNAL WORDS ................................................................................................ 1 1.1.3 COMPLIANCE WITH SAFETY REGULATIONS ........................................................................ 1

1.2 SAFETY OPERATION OF THE MACHINE ....................................................................................... 17 1.2.1 BEFORE STARTING THE ENGINE ............................................................................................ 17 1.2.2 AFTER STARTING THE ENGINE ............................................................................................... 19

1.3 SAFETY AND MAINTENANCE INSTRUCTIONS ........................................................................... 29 1.4 WARNING SIGNS AND ICONS ......................................................................................................... 36

1.4.1 PRODUCT NAMEPLATE ............................................................................................................ 36 1.4.2 THE LOCATION OF THE WARNING SIGNS AND ICONS ...................................................... 37

2 STRUCTURE AND TECHNICAL FEATURE ........................................................................................... 44

2.1 STRUCTURE OF THE WHOLE MACHINE ....................................................................................... 44 2.2 STRUCTURE AND DIMENSION ....................................................................................................... 47 2.3 TECHNICAL FEATURE ...................................................................................................................... 47

2.3.1 OPERATING WEIGHT ................................................................................................................. 47 2.3.2 ENGINE ......................................................................................................................................... 47 2.3.2a ENGINE ....................................................................................................................................... 47 2.3.3 RUNNING SYSTEM ..................................................................................................................... 48 2.3.4 TURNING SYSTEM ..................................................................................................................... 48 2.3.5 HYDRAULIC SYSTEM ............................................................................................................... 48 2.3.6 ELECTRIC SYSTEM .................................................................................................................... 48 2.3.6A ELECTRIC SYSTEM ................................................................................................................. 49 2.3.7 SERVICE REFILL CAPACITY .................................................................................................... 50 2.3.8 DIGGING PARAMETER .............................................................................................................. 50 2.3.9 DIMENSION OF CYLINDERS .................................................................................................... 52 2.3.10 BULLDOZING SYSTEM ........................................................................................................... 52 2.3.11 BUCKET CAPACITY ................................................................................................................. 52 2.3.12 CONTROL SYSTEM .................................................................................................................. 52

3 MACHINE OPERATION ......................................................................................................................... 58

3.1 WORKING TEMPERATURE PERMITTED ....................................................................................... 58 3.2 ENGINE STARTING ............................................................................................................................ 58 3.3 ENGINE STOPPING ............................................................................................................................ 58 3.3A ENGINE STOP ................................................................................................................................... 58 3.4 OPERATION TECHNIQUES ............................................................................................................... 58

3.4.1 WALKING ON SLOPE OR ON ROUGH ROAD SURFACE ...................................................... 59 3.4.2 TRENCHING ................................................................................................................................. 59 3.4.3 BACKFILL OR GRADING .......................................................................................................... 59 3.4.4 BUCKET FITTING ....................................................................................................................... 59 3.4.5 TRANSPORTATION ..................................................................................................................... 60

4 EXAMINATION AND MAINTENANCE .................................................................................................. 61

4.1 OPERATION AND MAINTENANCE IN WEAR-IN TERM .............................................................. 61

5 MAINTENANCE ......................................................................................................................................... 62

5.1 COMMONE EXAMINATION ............................................................................................................. 62 5.2 FUEL CIRCUIT .................................................................................................................................... 62

5.2.1 FILLING ........................................................................................................................................ 62

5.2.2 TANK CLEARANCE .................................................................................................................... 62 5.2.3 FUEL GUSHING PRESSURE EXAMINATION ......................................................................... 63 5.2.4 AIR OUTLET OF FUEL CIRCUIT ............................................................................................... 64 5.2.5 CLEAN OR REPLACE FUEL FILTER ELEMENT ..................................................................... 64 5.2.6 CLEAN INLET FILTER NET OF FUEL TRANSFER PUMP ..................................................... 65

5.3 COOLING CIRCUIT SYSTEM ............................................................................................................ 66 5.3.1 EXAMINATION OF COOLANT .................................................................................................. 66 5.3.2 EXAMINATION OF TRANSFER TUBE AND HOOP ................................................................ 66 5.3.3 CLEANING RADIATOR CORE ................................................................................................... 66 5.3.4 COOLANT REPLACEMENT ....................................................................................................... 66 5.3.5 COOLANT..................................................................................................................................... 67

5.4 HYDRAULIC SYSTEM ....................................................................................................................... 67 5.4.1 PRE-HEATING OF HYDRAULIC OIL ........................................................................................ 67 5.4.2 EXAMINE SURFACE OF HYDRAULIC OIL ............................................................................. 67 5.4.3 CLEAR WATER AND IMPURITY IN HYDRAULIC OIL TANK .............................................. 67 5.4.4 RENEW THE HYDRAULIC OIL AND CLEAN THE OIL FILTER ........................................... 68 5.4. 5 RENEW THE FILTER ELEMENT OF THE BACK OIL FILTER .............................................. 68 5.4.6 CHANGE THE OIL FILTER ELEMENT OF THE PILOT CONTROL SYSTEM ...................... 69 5.4.7 THE PRECAUTIONS WHEN USE THE HYDRAULIC HARMER ........................................... 70 5.4.8 CHECK THE PRESSURE ............................................................................................................. 70

5.5 ENGINE ................................................................................................................................................ 71 5.5.1 CHECK THE LEVEL OF THE ENGINE OIL .............................................................................. 71 5.5.2 RENEW THE ENGINE OIL ......................................................................................................... 71 5.5.3 CLEAN AND RENEW THE FILTER ELEMENT OF THE OIL FILTER.................................... 71 5.5.4 CHECK TENSION OF FAN BELT ............................................................................................... 72 5.5.1A CHECK THE LEVEL OF THE ENGINE OIL ........................................................................ 72 5.5 2A REPLACE ENGINE OIL ......................................................................................................... 72 5.5.3A REPLACE OIL FILTER ........................................................................................................... 73 5.5 4A CHECK DRIVE BELT AND TENSION OF FAN BELT ........................................................ 73 5.5.5 CHECK FIXING OF THE ENGINE ............................................................................................. 73 5.5.6 OTHER OPERATION OF ENGINE ............................................................................................. 74 5.5.6A OTHER OPERATION OF ENGINE ........................................................................................... 74

5.6 AIR FILTER .......................................................................................................................................... 74 5.6.1 CLEAN THE REAR LID .............................................................................................................. 74 5.6.2 CLEAR OR CHANGE THE FILTER ELEMENT IN THE AIR FILTER ..................................... 75 5.6.3 CLEAR ALL PARTS IN THE FILTER.......................................................................................... 75 5.6.4 CHANGE AIR FILTER ELEMENT .............................................................................................. 75

5.7 STORATE BATTERY .......................................................................................................................... 76 5.7.1 EXAMINE THE LIQUID LEVEL OF THE ELECTROLYTE ..................................................... 76 5.7.2 EXAMINE ACID AND CHARGE STATUS ................................................................................. 76

5.8 WALING SPEED REDUCER .............................................................................................................. 76 5.8.1 EXAMINE LUBE LEVEL IN EACH SPEED REDUCER ........................................................... 76 5.8.2 CHANGE LUBE ............................................................................................................................ 77 5.8.3 EXAMINE FIXING OF THE REDUCER..................................................................................... 77

5.9 GYRE SPEED REDUCER .................................................................................................................... 77 5.10 PEDRAIL ............................................................................................................................................ 78

5.10.1 EXAMINE AND ADJUST TENSIONING OF THE PEDRAIL ................................................. 78 5.11 SUPPORTING WHEEL, PEDRAIL WHEEL AND PILOT WHEEL ................................................ 78

5.11.1 EXAMING FIXING MOMENT OF SUPPORTING WHEEL .................................................... 78 5.11.2 THE OIL LEVEL OF SUPPORTING WHEEL, PEDRAIL WHEEL AND PILOT WHEEL ..... 78

5.12 LUBRICATE ....................................................................................................................................... 79 5.13 CHECK AND MAINTENANCE TABLE........................................................................................... 81 5.14 OIL SELECTING ................................................................................................................................ 82 5.15 LONG TERM STORE ......................................................................................................................... 83 5.16 MALFUNCTION AND SOLVING .................................................................................................... 84 5.14A OPTIONAL FUEL LIST .................................................................................................................. 88

I

FOREWORD

This manual contains a number of instructions and safety recommendations regarding

driving, handling, lubrication, maintenance, inspection and adjustment of the excavator.

The manual is to promote safety maintenance and enhance machine performance.

Keep this manual handy and have all personnel read it periodically.

If you sell the machine, be sure to give this manual to the new owners.

This machine complies with EC directive "2006/42/EEC".

1. Read and understand this manual before operating the machine.

This operator's manual may contain attachments and optional equipment that are not

available in your area. Please consult your local CARTER distributor for those items you

require.

Improper operation and maintenance of this machine can be hazardous and could result in

serious injury or death.

Some actions involved in operation and maintenance of the machine can cause a serious

accident, if they are not done in a manner described in this manual.

The procedures and precautions given in this manual apply only to intended uses of the

machine. If you use your machine for any unintended uses that are not specifically

prohibited, you must be sure that it is safe for you and others. In no event should you or

others engage in prohibited uses of actions as described in this manual.

2. Inspect the jobsite and follow the safety recommendations in the safety hints section

before operating the machine.

3. Use genuine CARTER spare parts for the replacement of parts.

We expressly point out that CARTER will not accept any responsibility for defects resulting

from non genuine parts or non workmanlike repair.

In such cases CARTER cannot assume liability for any damage.

Continuing improvements in the design of this machine can lead to changes in detail which

may not be reflected in this manual. Consult CARTER or your CARTER distributor for the

latest available information for your machine or for questions regarding information in this

manual.

II

BEFORE SERVICING THIS MACHINE

It is the responsibility of the owner and all service and maintenance personnel to avoid

accidents and serious injury by keeping this machine properly maintained.

It also is the responsibility of the owner and all service and maintenance personnel to avoid

accidents and serious injury while servicing the machine.

No one should service or attempt to repair this machine without proper training and

supervision.

All service and maintenance personnel should be thoroughly familiar with the procedures and

precautions contained in this manual.

All personnel also must be aware of any federal, state, provincial or local laws or regulations

covering the use and service of construction equipment.

The procedures in this manual do not supersede any requirements imposed by federal, state,

provincial or local laws.

CARTER can not anticipate every possible circumstance or environment in which this machine

may be used and serviced.

All personnel must remain alert to potential hazards.

Work within your level of training and skill.

Ask your supervisor if you are uncertain about a particular task. Do not try to do too much too

fast.

Use your common sense.

Noise and vibration Declaration

Noise：

Normal working:

LwA=100dB(A), uncertainty =1.5dB(A) Measured according to ISO 6395:2008; LpA=72dB (A), uncertainty =1.5dB (A); Measured inside the cab according to ISO 6396:2008;

Vibration: The vibration total value to which the hand-arm system is subjected does not exceed 2.5m/s2; the height root mean square value of weighted acceleration to which the whole body subjected is 5.3m/s2. Note: vibration levels are influenced by many different parameters. Many items are listed below: -Operator training, behavior, mode and stress; -Job site organization, preparation, environment, weather, and material; -Machine type, quality of the seat, quality of the suspension system, attachments, and condition of the equipment.

III

DECLARATION OF CONFORMITY

Declaration of Conformity

(Manufacturer’s Declaration)

We: Shandong Carter Heavy Industry Machinery Co., Ltd.

Economic Developing District of Linshu, Shandong Province 276715, P.R. China

declare in sole responsibility that the equipment

Product: Hydraulic Excavator Model: CT18, CT45, CT65, CT85, CT150 S/N.: CTA150135830003, CTG473433760017, CTC061331600006, CT6812554633890130, CT4BG1-99508735700016

to which this declaration applies, complies with the following directives and/or standards:

2006/42/EC EN 474-1:2006+A1:2009 EN 474-5:2006+A2:2012

Notes:

This declaration becomes invalid, if technical or operational modifications are introduced

without the manufacturers consent.

Person responsible for keep the technical file: Name, Surname: _________________

Address: __________________________________________

Person responsible for making this declaration:

Name and Signature: Zhong Yuzhu (钟玉柱)

Date and Place: 2013-06-15 Linshu, Shandong, P.R. China

The title of signature: Assistant Chief Engineer

IV

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Machine Serial No.

Engine Serial No.

Manufacturing year

Manufacturer

Address

SAFETY－Safety information

1

1 SAFETY 1.1 SAFETY INFORMATION

1.1.1 RECOGNIZE SAFETY LABEL

(a) This is the label of “safety”.

(b) When you see this label on the machine or in this manual, you should be

aware that it reminds of the risk of injury.

(c) Please follow recommended precautions and safe practices.

1.1.2 UNDERSTAND SIGNAL WORDS

The safety signs on the machine which indicate the degree of harm DANGER, WARNING or

CAUTION and the mark is used in conjunction with signs on the machine safety signs.

DANGER indicates a hazard with a high level of risk which, if not avoided, will result in death or

serious injury. Safety signage is positioned on the particular hazard nearby.

WARNING indicates a hazard with a medium level of risk which, if not avoided, could result in death

or serious injury. Safety signage is set in a particular crisis in the vicinity.

CAUTION indicates a hazard with a low level of risk which, If not avoided, may cause in minor or

moderate injury. General precautions listed in the CAUTION safety signs. In the present manual, the

IMPORTANT is also used to remind the attention to the safety instructions.

To avoid confusion between the machine protection and personal safety instructions, the signal word

"important" is used to indicate a situation that may cause damage to the machine.

To do additional description of the individual important information.

1.1.3 COMPLIANCE WITH SAFETY REGULATIONS

(a) Read and observe all safety signs carefully, machine


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and this manual all safety related issues in the safety

signs marked on the machine and in this manual.

(b) When necessary, installation, maintenance and

replacement of safety signs.

(c) If the safety signs or the manual is damaged or lost,

by an order like the same method ordering spare parts to

the specified sellers and CARTER Heavy for ordering

them (Order required specifying the model and serial

number of the machine).

(d) Learning to operate and control the machine safely

and correctly.

(e) Only trained and qualified personnel can be allowed

to operate the machine.

(f) Keeping the machine in a suitable working

conditions

(g) Make unauthorized modifications of the machine

may be detrimental to its function and (or) security, and

affect the life of the machine.

(h) The safety instructions in the "Security" chapter are

basic safety instructions of the machine. However, these

safety instructions don’t involve all the dangerous

situations you may encounter. If have any doubt, please

contact with you specifies dealer or CARTER service

engineer firstly before operating and maintaining of

machinery.

1. Understand the safety equipment

(a) Ensure that all guards and cover are in the

appropriate location. If the guards and the cover are

damaged, please repair them immediately.

(b)Understand the method of using the safety device

and use it correctly

(c) Do not remove any safety devices, and to ensure that

they remain in good working condition.

2. Keep machine clean

(a) If there is water in the electrical system it could

cause the machine failure. Do not use water or the steam

to flush electrical system such as sensors, connectors

(b) When checking or maintenance, if the machine with


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mud or oil, it may result in the risk of slipping, falling

and harming eye by dirty things. So please keep the

machine clean...

3. Keep cabin in clean

(a)When entering the cabin, be sure to remove dirt and

grease under the shoes. The operation of the pedal with

the shoes carrying mud or oil, the foot will slip which

could cause a serious accident.

(b) Do not leave parts or tools in the cabin.

(c) Do not stick suction pad to the glass. Suction pad

play the role of magnifying function, it may cause a fire.

(d) When driving or operating machinery, do not use a

mobile phone in the cabin.

(e) Dangerous goods (such as flammable or explosive

materials) should not take into the cabin.

4. To leave the seat in a locked condition

(a) Operator stood up from the seat, such as opening or

closing the front Window or roof windows, or adjust the

seat, has to make the work unit is completely lowered to

the ground, the safety lock lever firmly pull into the

locked position, and then turn off the engine. If the

control joystick is not locked, and accidental touching

the joystick, the machine may move suddenly and

causing serious injury or damage to the machine.

(b) When leaving the machine, be sure to operating

device is fully lowered to the ground, Safety lock lever

firmly pull into the locked position, and then closed

engine. With a key to lock the device, then remove the

key and placed in a predetermined position.

5. Emergency preparedness

Take precautions against fire or accident

(a) Prepared and placed first aid kit and fire extinguisher

equipment nearby.

(b) Carefully read and understand the instructions

attached to the fire extinguisher and correctly use the

fire extinguishers

app:ds:take

app:ds:precautions

app:ds:against


4

(c) Make the emergency guide measures to deal with

fires and accidents.

(d) The telephone number of Doctors, ambulance,

hospital, and fire department should be sticked by the

phone.

6. Wear protective equipment

Wear tight clothing and safety products suitable for

work.

You may need the following safety products:

• Hard helmet

• Safety Shoes

• Safety glasses, goggles or face shield

• Heavy duty gloves

• Hearing protection

• Reflective clothing

• Rain gear

• Masks or filtration masks

Always wear work clothes and safety supplies, do not

leave things to chance.

Avoid wearing loose clothing, jewelry or other things

may be hooked by joystick.

Safe operation of the machine requires the operator to

concentrate. Do not listen to the radio or music while

operating.

7. Noise protection

(a) Prolonged exposure to loud noise can cause hearing

impairment or loss.

(b) Wear suitable hearing protectors, such as ear plugs

to avoid harmful or strong unpleasant noise.

8. Check machine

(a) To avoid personal injury, every day before starting

the machine, check the machine carefully.


5

(b) In the tour check carefully around the machine, be

sure to “check before the start of the inspection”

described in the chapter all.

9. Use handrails and ladders

Always observe this precaution to ensure safety!

(a) The drop is one of the main causes for personal

injury.

(b) Up-and-down the machine, always with the pedal

and handrails to maintain three points of contact, and

machine-oriented.

(c) Do not put any lever, the cabin door handle as a

handrail.

(d) Can not jump on/off the machine, and do not get

on/off the moving machine..

(e) When using the machine, pay attention to the


6

platform, pedals and handrails slippery.

(f) Oil, mud and water in pedals, handrails and shoes

should be cleaned any time.

10. Adjust the position of the seat

(a) Uncomfortable seat is likely to cause fatigue, leading

to operational mistake.

(b) In each exchange machine operator, and should be

re-adjust the position of the seat.

(c) When the operator back on seat back, you should be

able to step on the pedal to the end, and correct the

operation of the joystick. If not, move forward and

backward seat, re-adjust.

11.Fasten seat belts

(a) In the case of a rollover accident, the operator may

be injured or throwing out of the cabin, or may be

pressing down by the machine, then cause serious injury

or death.

(b) Before operating the machine, check the seat belts,

buckles and solid set pieces carefully. If you find any

damage of the seat belts, it should be replaced before

operating.

(c)While operating the machine, be sure to sit on the

operating chair and fasten your seat belts, in order to

minimize the possibilities of accident injuries

(d) Best to replace seat belt per three years, no matter

what condition it is.


7

12. Not-allowed to get on/off the machine at will

(a) Do not jump on/off the machine when it’s moving.

(b) If the machine begins to move in the absence of the operator, do not jump on the machine and tried to

stop it.

13. Not allowed to sit on the machine at will

Do not allow anyone sitting on a bucket or other attachments, or it may falls and cause serious injury.

14. Windshield cleanout fluid

Use ethanol-based washing liquid to clean the windshield. Do not use methanol the base washing liquid,

otherwise it will stab your eyes.

15. Cabin window glass

(a) If the glass at the working device side of the cabin is broken, there is risk of the working device

coming in direct contact with operator's body, so stop the operating immediately and replace the glass.

(b) If the damage to the roof window made of Plexiglas (polycarbonate), they will explode and lose their

protective function; roof window has been damaged by a falling rock or burst, be replaced with a new

window.

16. To ensure a good vision

(a) To ensure safe operation or walking, to check if anyone in the area around the machine or disorders

and workplace.

(b) When working in a dark place, turn on work lights and headlights on the machine, if necessary, set the

auxiliary lighting in the work area.

(c) If the vision is not good, as fog, snow, rain or dust, to stop the operation.

17. View the Construction site in advance

(a) When working on the side of ditch or the road

shoulder, the machine can turn over; this will cause

serious injury or death.

(b) Prior to survey the terrain and ground conditions of

the site, in order to prevent the machine to tip over or

fall, or even the ground, stockpile or the river bank

collapsed.

(c) The development of operational plans to use the

machine for your job or site.


8

(d) As required reinforcement the ground, ditch side and

road shoulder, to ensure a safe distance between the

machine and ditch and road shoulder.

(e) When operating in diagonally or shoulder of the road,

according to need to arrange signalman command.

(f) Before starting work local in trust between soft, must

be reinforced ground.

(g) Operations on the frozen ground, to be especially

vigilant. Because the ambient temperature rise to causes

the ground to become soft and slippery.

18. Prevention of falling stones and gravel

(a) Work in the condition where may fall rocks or stone,

to ensure that the cabin is equipped with falling object

protective net.

(b) Wear a helmet and protective eyewear.

19. Multi-machine operation signaling

In the case of multi-machine operation so that all

workers unified signal, specify a signalman to organize

the job, while ensuring that all workers obey the

command.

20. signalman signals and gestures

(a) To set the flag on the shoulder or soft ground. If the

vision is not good, if necessary, arrange for a signalman

command. The operator should pay particular attention

to the signs, and obey the command of the signalman.

(b) Only signaled by one signalman.

(c) Before starting work, ensure that all operators are

aware of all signals and gestures.

21. Keep away from rotating parts

(a) It maybe results in serious injury if caught in moving

parts.

(b) Working next to the rotating member, need to be

very careful of hands and legs, clothes, jewelry and hair

so that will not rotating member involvement.


9

22. Prevent parts flying out

The track adjusters grease usually in the high pressure,

if not avoided the following precautions may result in

serious injury, blindness or death.

(a)Do not remove the grease fitting or valve parts.

(b)Parts could come out of, so the body and face should

be away from the valve body.

(c) Walking reducer with pressure.

(d) As part could come out, so the body and face must

be away from the air drain plugs, to avoid injury.

(e)Because the gear oil is hot, gradually release air

emissions tied to wait for gear oil cooling, the pressure

was released.

23. Prevent falling objects, flying objects and invader

(a) Falling objects, flying objects and invader hit or

enter the driving cabin dangerous workplaces,

depending on the operating conditions; security

mounted the necessary shield to protect operating

personnel.

(b) When the removal or crushing operation, to install

the front shield, and posted the front glass transparent

cellophane.

(c) When the risk of falling rock mine or quarry

operations, to install FOPS (Falling Object Protective

Structure) and the front shield and posted in the glass

transparent cellophane.

(d) When the operation to close the front window.

Further, to ensure that other persons out of the danger

zone, and keep a safe distance.

(e) Above described is for typical conditions, according

to the site operation, you may need to install other guard.

When any part of the protection structure, like ROPS,

FOPS, and TOPS (rollover protection structure), and so

on appear the plastic deformation or fracture (for

example, subject to due to roll, Falling Object shocks or

tipping) , please contact with CARTER Heavy Industry


10

dealer in a timely manner, the protective structure has to

be replaced according to manufacturer’s specifications.

24. To prevent burns

(a) The discharge of the high temperature liquid:

• Machine operation, the cooling water of the engine is

hot and pressure. If the skin is exposed to a spill or

spray of hot water or steam will cause serious burns.

• When the engine is hot, do not open the radiator Cover,

and first slowly rotate the lid to be fully released off the

pressure, then remove the cover and release the

pressure.

• Hydraulic tank is pressurized to ensure release the

pressure before the lid is removed.

(b) High-temperature liquid and surface:

In operation, the engine oil, gear oil and hydraulic oil

will become hot. Engines, hoses, tubing, and its parts

become hot. It should wait until oil and component

cooling only after inspection or maintenance work.

25. Prevent falling

(a) Storage of accessories, such as a bucket, May topple

over, resulting in serious injury or death.

(b) Safely store accessories and machinery to prevent

falling. Children and other non-essential personnel

should stay away from the storage area.

26. Be careful high-pressure liquid

(a) Pressure injection diesel oil, hydraulic oil, liquid


11

penetrate the skin or injected into the eye, resulting in

serious injury, blindness or death. Therefore, before

demolition hydraulic or other pipeline must release the

pressure in order to avoid these dangers.

(b) Tighten all the links before increase the pressure.

(c) With cardboard to find if it is leak, pay attention to

protect your hands and body free from exposure to the

high-pressure liquid. Wear a face shield or goggles to

protect the eyes.

(d) If an accident occurs, immediately accepted

professional surgeon treatment. Any liquid in to the skin

must be surgical remove in several hours; otherwise it

will lead to gangrene.

27. Prevent fire

(a) Check the oil spills

• Fuel oil, hydraulic oil and grease leaks may cause fire

disaster.

• Check whether the holder is missing or loose, the hose

is twisted Knot, or hose, piping friction between oil

cooling is damaged, and oil cooler flange bolts are

Relaxation, in order to avoid oil spills.

• The tightening, repair or replace any missing,

relaxation or damage the holder, piping, hoses, oil

cooler and its law blue bolt.

• Do not bend or strike high pressure lines.

• Do not install bent or damaged pipe, tube or hose.

(b) Check the short circuit

• A short circuit will cause a fire.

• Clean and tighten all circuit connections.

• In each shift before or after 8-10 hours of operation,

check the cable and wire is loose, kink, hard or cracked.

• Before each shift, or 8-10 hours after the operation,

then check stud end cap is lost or damaged.

• Do not operate the machine if cables or wires relaxed

and kinked.

(c) Clear combustibles

• Spilled fuel and hydraulic oil, garbage, grease, broken

debris and other combustible materials may cause a fire.


12

Check and clean machine every day, promptly remove

spilled or accumulation of combustible material, to

prevent fire.

(d) Check the key switch

Fire if not stop the machine, it will increase the fire

situation is not conducive to the fire. Daily before

operating the machine must to check the function of the

key switch, to start the engine, in order to idle speed

no-load operation, the key switch to OFF position, and

confirm whether the engine is came to a halt or not.

(e) To prevent lighting equipment cause an explosion

• When checking the fuel, oil, battery electrolyte,

windows Washing-up liquid coolant, to use

explosion-proof lighting equipment. If not use this kind

of lighting equipment, the explosion caused serious

injury.

• When the power of the machine used for lighting, to

comply with the prescribed instructions.

(f) Check the heat shield

• Shrouds damage or loss may cause a fire.

• If any abnormalities are found, make sure before

operating the machines Repair or coupled with new heat

shield.

28. Measures in the event of fire

(a) If the fire breaks out, evacuated machines as the

following:

• If time permits, switch the key to the OFF (off)

Position, stop the engine.

• If time permits, use of fire extinguishers,

(b) In case of emergency, if not open cabin or the front

window, take the hammer and break the rear or side

glass, to escape from the cabin.

29. Avoid heating near the hydraulic lines

Flammable spray will been burned in the vicinity of the

pressure tube heating, which will lead to you and others

next to you severely burned.

• Do not welding, soldering or gas welding nearby the


13

hydraulic pipe or other flammable materials.

• When Burning over directly combustion area, the

hydraulic pipe may be cut off at any time. The machine

should be install temporary jacket to protect hoses or

other materials while welding, soldering and other

operations.

30. Avoid heating pipes where there are flammable

liquids.

(a) Do not welding or gas cutting pipes or hoses where

contain flammable liquid.

(b) Before welding or gas cutting pipes, completely

cleared flammable liquid with non-combustible solvent.

31. Remove the paint before welding or heating

(a) Paint may produce harmful gases in welding,

soldering, or using the gas torch; inhalation of these

gases can cause nausea.

(b) Prevent to producing potential toxic gases and dust.

(c) Removal paint in outdoors or in a well-ventilated

place. Correct disposing of the paint or solvent to

protect the environment.

(d) Remove the paint where need to weld or heat:

• Wear respirator to prevent inhalation of dust, if using

sandpaper and grinding wheels to remove the paint.

• Using Soap liquid to remove the paint or varnish

removers before welding if you use solvent or varnish

removers to remove the paint. Clear the solvent or paint

remover’s containers and other flammable materials in

the working area. Waiting at least 15 minutes before

heating or welding for dispersed the volatile gas.

32. Prevent battery exploding

（a）Battery gas could explode.

• Avoid sparks, lighted matches and flame close to the

top of the storage battery .

• Using a voltmeter or aerometer to check up the

battery power, not use the method of placing a metal

contact the electrode.

app:ds:storage

app:ds:battery


14

• Do not charging to the frozen battery, otherwise it

would cause explosion. The battery should be warmed

to 16℃.

(b) Electrolyte of battery is poisonous. If the battery

were exploded, battery electrolyte is splashed into the

eyes which could lead to blindness.

(c) Be sure to wear goggles when checking the specific

gravity of electrolyte.

If the Sulfuric acid were spilled on the body accidentally, should process as follows:

• First, flushing skin with water.

• Then, using soda or lime to neutralize the acidity.

• Addition, rinsing with water for 10-15 minutes and seek medical advice immediately.

33. Ventilating of the closed area

If must start the engine in a closed area, or disposing of

fuel, cleaning oil or paint, be sure open the door and

windows to adequate ventilation to prevent gas

poisoning。

34. To prevention the risk of asbestos dust

(a) If inhaled asbestos dust in the air were caused lung

cancer. When engaged in demolition work in the

workplace or treatment of industrial waste, it has the

dangers of asbestos inhalation. Be sure to observe the

following rules


15

• When cleaning, water sprays dust suppression, do not

use compressed air to clean.

• If there are asbestos dust in the air, must be in the

limelight position to operate the machine, all personnel

should use qualified dust masks.

• Other people should not be close to the machine when

working.

• To comply with regulations, rules and environmental

standards in the workplace.

(b) This machine does not use asbestos, but counterfeit

parts may contain asbestos, so be sure to use CARTER

spare parts.

35. Safety handling the chemicals

Direct contact with harmful chemicals on the human

body can cause serious injury. The chemicals used in the

present machine, such as lubricants, coolants, paints,

and a binder, may be harmful.

• Material Safety Data Sheet provides the details of the

chemicals on the human body and health hazards, safety

procedures and emergency measures.

• Before using the hazardous chemicals should be

verified with the data table, so will be able to really

understand the danger, and know how to conduct

security operations, and then work in accordance with

the procedures using the recommended tools.

• Chemicals Safety Data Sheets (MSDS)which used in

machine should be obtained from the local dealer and

the service division of CARTER。

36. Proper waste disposal

(a) Disposing the waste improperly may harm to the

environment and ecological .The potentially hazardous

waste in CARTER heavy equipment, including

hydraulic oil, fuel, coolant, refrigerant, filters, and

batteries and other items.

SAFETY－Safety operation of the machine

16

• In the discharge of liquid, should be use leak-proof

containers. Do not use food or beverage containers,

because it may lead to accidental ingestion.

• Do not pour the waste into the ground, sewers, or

poured into any water source.

• Refrigerant leak into the air can destroy the Earth's

atmosphere. Government regulations require a certified

air conditioning service center to recovery and recycling

of refrigerant.

(b) Inquire local environmental, recycling center or your

dealer about the correct ways of how to recovery or

disposal of waste.

37. Installed accessories

(a) When installing the optional accessories, exist security or legal constraints, so please contact with

CARTER dealer in advance.

(b) CARTER is not responsible for the injury caused by using of unauthorized accessories or parts.

(c) When installing and using the optional accessories should read the accessories manual or manual

attachment.

38. Attachment combination.

(a) Different types or combinations of the working apparatus may cause the risk of collision the driver's

cabin or other components of the machine.

(b) Before using unfamiliar working device, please check whether there is the risk of interfering with

each other, and work carefully.

39. Unauthorized modification

(a) Before modification you should have to contact with CARTER dealer. Any modification without

approval of CARTER will cause dangerous.

(b) In the case of without the approval of the CARTER, for any harm caused as a result of the

modification, accident or product failure, CARTER assumes no liability whatsoever.


17

1.2 SAFETY OPERATION OF THE MACHINE

• The machine is not intended for use in unhealthy enviroments, e.g. contaminated areas. • The machine is not intended for operation with a hydraulic- or demolition-hammer.

Hydraulic excavator CT150 is suitable for I-IV soil excavation and loading operations. In the mechanized

construction of industrial and civil construction, transportation, road construction, water resources and

electric engineering, farmland transformation, it can be widely used for excavation pit channel, backfill

pavement, earth mining, digging build subgrade, stripping, mining and so on.

1.2.1 BEFORE STARTING THE ENGINE

1. The check before starting the engine

· Wipe away the dust on the surface of the window glass, to ensure a good vision.

· Clean the headlights and work lights well, and check whether they are normal.

·Check the coolant level, fuel level and engine oil sump oil level.

· Check the air filters if it is blocked, and check the wires for damage.

· The seat adjusted to the easy operation, and checks the seat belt or the retaining clips damage or not.

· Check that the instrument is working properly, check the light and the angle of the lights and check the

control lever is all in the middle position.

· Adjust the rearview mirror, so that you can clearly see from the seat and the back of the machine.

·Make sure there are nobody and barrier around the machine.

2. Safety regulation for starting the engine

(a) When starting the engine, honking for warning.

(b) Only allows the driver to start or operate machine.

(c) In addition to the operator, does not allow anyone on the machine.

(d) Not allowed to start the engine by the way of which cause the starter motor short circuit, doing so is

not only dangerous, but also cause damage to the equipment.

Starting engine in cold weather

(a) To complete warm-up operation. If the machine before operating the joystick does not warm up

thoroughly, there will be unresponsive, resulting in accidents.

(b) If the battery electrolyte is frozen, not to charge the battery or use a different power to start the

engine, otherwise the battery will be the risk of fire.

(c) Charging or with different power before starting the engine, make the battery electrolyte melt,


18

before starting to check the battery electrolyte freezing and disclosure.

4. Safety removes and operate machine

(a) Surrounding personnel are likely to be knocked

down

• Especially careful not to knock down around the

staff, before moving, rotating or operating

machinery, recognized around the location.

• Always keep walking alarm horn (option) in

working condition. When the machine begins to

move, they can warn around personnel.

• Walking in the narrow area, rotary or operating

machinery arrangement signalman command,

before you start the machine, to coordinate the

meaning of the gesture signal. The signalman was

the only, and shall not at the same time more than

two signal officer commanding.

(b) Sitting in the operating chair

• Only start the engine in the operating chair

• Never stand in the track above the ground to start

the engine.

• Before starting the engine, confirm that all the

joystick in the middle position.

The incorrect engine start procedure will cause the machine out of control, could result in serious injury

or death.

The safety lever only in the locked position to start the engine, you can not start the engine in the

unlocked position.

(c) Jump start

• Battery gas may explode and cause serious

Casualties.

• If you must jump start the engine machine, be

sure to comply with the "operating the engine in

the chapter.


19

this requirements need two people to carry.

• Never use a frozen battery.

• Failure to observe proper jump start step will

result battery explosion or loss of control of the

machine.

(d) To avoid machine equipped with crew

• Only allow the operator on the machine, do not

allow other multiply member.

• The crew will also block the vision of the

operator, resulting the unsafety of the operation.

The crew on the machine is vulnerable to injuries, for example, hit by foreign objects or thrown from

the machine.

The decorative Vice seat in the cabin allows equipped with a ride staff.

1.2.2 AFTER STARTING THE ENGINE

1. After starting the engine check

(a) When doing inspection, moves the machine to a wide area without any obstacle, and slowly operates

the machine, does not allow anyone close to the machine.

Who operate close to the machine?

(b) Be sure to fasten your seat belt.

(c) Inspect the operation of instruments and equipment is functioning properly, and check the bucket,

stick, boom, travel system, rotary system. And the steering system is operating correctly.

(d) Check the machine's sound, vibration, heat, smell or instrument whether there is abnormal, check the

oil or fuel leaks.

(e) If any abnormality is found, to be repaired immediately.

(f) To be maintenance, switch the safe operation lever to the LOCK position and suspension overhaul

signage.


20

2. machine direction

In the present specification, front, rear, left and

right refer to the cabin when facing the front,and

the drive wheels in the rear of the machine, when

the traveling direction as seen from the cabin.

3. Confirm the direction of travel of the machine

(a) Before driving the machine to confirm the

position of the lower part of the vehicle body and

operation

Personnel relations:

• If the motor running beneath the cabin, when

forward brake pedal / lever, the machine will move

backward.

• When the guide wheel is located under the cabin,

to move forward the brake pedal/ lever, the

machine will move forward.

(b) In the lower portion of the vehicle body inner

side of the machine, paste with directions card.

When the operator move forward the pedal / lever,

the head pointing ways of the signs arrows is the

actual direction of travel of the machine.

Walking pedal / lever mishandling can cause serious injury or death.

4. Walking safety rules

(a)When using the machine, in order to prevent the

stall due to an overload stall and to avoid the loss

of working device, do not exceed the most of the

machine allowable load or performance.

(b) when walking on flat ground, to recover the

working device and keep the ground height of

40-50cm (16-20in).

(c) when walking on rough ground, walking to idle,

and does not to swerve, otherwise the machine

will have to overturn. When the working device

hit the ground, the machine out of balance, or

would bad machines or structure.


21

(d)When walking over rough terrain or on steep

slopes, if the machine is installed downspeeding

device, switch off(take off) the automatically

downshift. If the automatic deceleration switch is

turned on, the engine speed will mention high,

walking speed suddenly accelerated.

(e) As far as possible, avoid walking on obstacles,

if the machine had to walk on the obstacles, to

make the device close to the ground and

low-speed walking. Do not cause the machine to

violent tendencies walking on the side of the

obstacle.

(f) When walking or operation, must be with

people, buildings, or other machines to maintain a

safe distance to avoid contact with them.

(g) When passing on from bridges or buildings, to

first check whether the structural strength

sufficient to support the weight of the machine.

(h) When walking on the road, first of all the

relevant authorities to check and follow their

guidance.

(i) When in the tunnel, bridge, wire or other highly

limited operation to slow the operation, and to pay

special attention not to let the working device to

come into contact with any thing.

5. Driving machine safely

(a) Before moving the machine, make sure the

direction of travel and how to move step board or

joystick.

(b) Pressing the front portion of the pedal walking

or forward implementation of walking poles, so

that the machine

Move towards the guide wheel. (On the right track

operation,With reference to the pedal, the

operating lever to the part of the driving machine )

(c) Walking in the slope may cause the machine to

slip or tip over, resulting in serious injury or death.

(d) The slope walking, keep away from the ground

to make the working device 20-30cm (8-12in). In

case of emergency, you can quickly drops the


22

work apparatus on the ground in order to help

anchor the machine.

(e) When walking uphill,transferred the the cabin

facing the uphill direction.When walking

downhill,transferred the the cabin facing the

downhill direction..

(f) When walking, be sure to check the hardness of

the ground in front of the machine.

(g) when walking on steep slopes, Stretch the

working device in front ,in order to improve

balance, keep the distance from working device to

the ground 20-30cm(8-12in) and low-speed traffic.

(h) when going downhill, reduce the engine speed,

keep the travel lever maintained at a position close

to the "median", and walking at a low speed.

(i) Walking on the slopes straight up, straight

down, because on the slopes steering or across the

slope is very dangerous.

(j) Do not turn on slopes or across the slope. Be

sure the next to a flat place to change the location

of the machine, and then on the ramp slope.

(k) To the low-speed walking on the grass, leaves

or wet steel,The machines also have a risk of

slipping, even in the case of a small slope.

(l) If the engine is turn off when the machine is

walking on the ramp, move the joystick to the

"median",and then restart the engine.

6. To prevent the machine out of control causing

injury

(a) when the machine should parked on the level

of the ground as much as possible

(b) Do not park the machine on slopes.


23

(c) The bucket and other tools are lowered to the

ground.

(d) The throttle control knob gear down to 1st

gear.

(e) In the low-speed no-load operation of the

engine 5 minutes, allowing the engine to cool.

(f) Stop the engine, remove the key from the key

switch.

(g) Move the safety lever to the locked position

shown on the photos.

(h) If the machine must be parked on a slope,

apply the stopper to withstand both sides of the

tracks, and lowered the bucket, and insert the

bucket teeth into the ground.

(i) positioning the machine, to prevent rolling.

(j) Parking the machine in the appropriate place

far from other machines .

If you attempt to climb or block mobile machines, it is possible the occurrence of serious injury or

death.

7. Prevent reversing and rotary injuries

In order to prevent reverse rotation of an

accident:

(a) Before reversing and rotary look around,

recognized no one around the machine.


24

(b) Keep walking alarm device (option) in

working condition.

(c) Always be alert if anybody into the work area,

before moving the machine ,warning others horn

or other signal.

(d) In reverse, if your vision is blocked, to

arrange the signalman Command, and to always

keep the signalman in the field of vision.

(e) In the working condition of need

signalman ,using the local regulations potential

signal.

(f) Only if the signal and operators, who clearly

understand the signal,and then move the machine.

(g) Understand all the meaning of banner used in

the work, signals and marked, and confirm who fat

signal.

(h) Remain intact windows, mirrors and lights is

clean and undamaged.

(i) Dust, rain, fog will reduce visibility. When the

visibility is down, slow down, and the use of

appropriate lighting.

Reversing or turning on the machine, if someone in the vicinity of the machine, will be hit by a machine

or overwhelming, resulting in serious injury or death.

8. Prevent access to the work area

People are likely to be knocked down,even injured

when doing rotating .

(a) All people must be away from working area.

(b) Before operating the machine, Set a good fence

beside the rear of the bucket radius and back, in

order to prevent personal injury or damage to the

machine.

9. Do not put the bucket towards any person

Bucket lifting, moving or rotating absolutely can


25

not go through any person or the top of the truck

cabin.If the fall of the material in the bucket or

bucket collision may result in serious personal

injury or damage to the machine.

10.Prevent emptied

(a) In order to ensure that to evacuate from

Mizobe foundation collapsed, make sure the travel

motor is in the back,the vehicle body is placed

perpendicular to the gutter machine.

(b) In the foundation began to collapse and the

machine could not withdraw, do not panic, at this

time, and lower the working device is generally

fixed machine.

(c) Excavation work to avoid the hollowing out of

the soil of the bottom of the machine.

11. Prevent roll-over

(a) Do not try to jump out of the machine being

dumped, otherwise it will cause serious or fatal

crush.

(b) Dumping speed of the machine faster than the

speed you jump out, do not leave things to chance.

(c) Be sure to wear seatbelts.

(d) Operation on the slope, there is the risk of

roll-over could result in serious injury or death.

In order to prevent roll-over:

(e) Operation of the slope with caution.

• Smooth machine operation area.

• The bucket lowered to the ground and close to

the machine.

• Slowing down the speed of operation, and

prevent the roll-over or skidding.

• Avoid changing the direction of the slope

walking.

• If the slope across the inevitable, never crossing

slope greater than 15 degrees above the slope.

• Slow down the rotation speed of rotation of the

load, depending on the circumstances.


26

(f) Operating in the frozen ground to be

careful ,because the temperature rise will cause the

ground to soften the ground unsteady gait.

12. To prevent collapse

From the lower part of the excavation may cause

the edge of collapse or landslide, resulting in

serious injury or death

13. Beware of underground facilities

Underground cables or gas pipes are accidentally

cut may cause an explosion, fire, leading to the

occurrence of serious injury or death.

(a) Prior to excavation, check cable, gas and water

pipes position marked, or to confirm its position.

(b) Keep certain distance with cables, gas pipes

and water pipes .

(c) If cut fiber-optic cable due to an accident, do

not pay attention to the end of the cable.

Otherwise, the eyes may cause severe damage.

(d) If the Mining Hotline instructions in your area,

please contact; or direct contact with the local

utility company, so that they clear all underground

cables, pipes.

14.Beware of overhead bridges and other facilities

If the operating units of the machine or other parts

of the elevated hit the bridge,

Machines and overhead material will be damaged

and may cause injury, be sure to be careful.

15. To avoid the transmission line

(a) If the machine or device does not keep a safe

distance with cable, may cause casualties and

accidents.

(b) when operating near the wire , avoid any part

of the machine move to the place of the wire

length over to 3 m plus 2 times the length of the


27

line insulator distance.

(c) Verify and comply with all applicabinle local

laws and regulations.

(d) Wetlands will increase the range of possible

electric shock. Should be allowed other persons

around away from the work area.

16..Secure parking machines

In order to prevent accidents:

(a) The machine is parked on a level surface.

(b) The bucket shall be used to immobilize the

machine.

(c) The throttle control knob gear down to 1st gear.

（d) To the low-speed no-load operation of the

engine 5 minutes.

(e) Switch the key to OFF (off), stop the engine.

After the engine is stopped, turn the key switch to

“on” position, put safety lever at UNLOCK

position, shaking each joystick to escape residual

pressure in the hydraulic circuit and pneumatic

circuit.

(f) Remove the key from the key switch.

(g) The safety lever pulled at Lock (locked)

position.

(h) Closed windows, skylights and cabin door.

(i) Lock all access doors and box room.

17. Handing fuel - to prevent fires

(a) Handing fuel safely, because it is highly

flammable.If fuel is ignited, it will explode and (or)

fire, resulting in

Personal injury or death.

(b) When filling fuel oil,make sure no smoking or


28

fire around.

(c) Before refueling, be sure to stop the engine.

(d) Add fuel outdoors.

(e) All of the fuel and most of the grease agents

and some coolant are all flammable..

(f) Flammable liquids stored in a place away from

the risk of fire.

(g) Do not incinerate or puncture the pressure

vessel.

(h) Do not store oily rags, they can be lit fire

spontaneously to burn.

18.Safety transport

(a) In the truck or trailer plate loading and

unloading machine, the machine will be overturn.

• When moving machine from road transport, be

sure to comply with local regulations.

• Provide for the transportation of the machine to

the truck or trailer.

(b) Loading and unloading the machine, please

note the following:

• Select a firm level ground.

• Be sure to use the loading dock or slope.

• When loading or unloading machinery, there

must be a signalman.

• Loading and unloading machine, you must turn

off the auto-idle switch to avoid the operating

lever accidental operation and cause a sudden

increase in speed.

• Switch to select slow walking.Fast

walking ,speed will automatically increase.

• Shift on an incline is extremely dangerous ,and

should be avoided in the lower slope steering. If

SAFETY－Safety and maintenance instructions

29

you need to turn the machine,you should be

directed back to the ground or car plate, then onto

the slope correction direction.

• In addition to the travel lever onto or driving

under the slope, do not operate any other joystick.

• The top of the slope and flat relative to the

Survey Office was convex, care should be taken to

passing.

• Rotary car to prevent injuries may cause the

machine to tip over.

• Keep the arm pulling and slowly turn the car in

order to get the best stability.

• Chain or rope to hold the machine frame. For

more information, see the "Transport" chapter.

19. Prohibition the lifting

Hanging objects falling around may be hit by

falling objects or suppress, resulting in serious

injury or death.In order to prevent accidents, in

any case, prohibition lifting.

Prohibit hanging grasping logs, etc.

Prohibit hanging grasping logs, etc.

1.3 SAFETY AND MAINTENANCE INSTRUCTIONS

1. In order to prevent accidents:

(a) Understand the maintenance procedures before operating.

(b) Keep the work area clean and dry.

(c) Do not spray or steam in the cabin.


30

(d) When the machine is moving, not the machine lubrication or maintenance.

(e) To avoid the hands, feet and clothes touch with rotating parts.

2. Before maintenance of machine

(a) Park the machine on level ground.

(b) The bucket is lowered to the ground.

(c) The throttle control knob gear down to 1st gear.

(d) low-speed no-load run the engine for 5

minutes.

(e) The key switch to the OFF (OFF) position,

stop the engine.

(f) Move around a lever to release the pressure in

the hydraulic system.

(g) Remove the key from the key switch.

(h) In the control rod to hang the "Do Not

Operate" sign.

(i) Pull the pilot control lever to the locked

position.

(j) cooling the engine.

(k) If maintenance must be in the state of the

engine is running, please do not let anyone on the

machine.

(l) If maintenance must lift the machine, should be

maintained within 90-110 ° angle between the

boom and stick. Firmly supporting any part of the

lifted on the machine.

(m) Non-operating in passive arm lift machine.

(n) Regular inspection of certain parts ,do repair or

replacement if needed. Refer to the manual

"maintenance" chapter of the content.

(o) Keep all parts in good working condition and

properly installed.


31

(p) Timely processing of damaged parts,

replacement of worn or broken parts. Clear any

accumulation of grease, oil or debris.

(q) Before adjust the electrical system or welding

on the machine , be sure to disengage the battery (-)

ground cabinle.

3. Warn others machine maintenance

(a) Unexpected machine movement can cause

serious injury.

(b) Before doing any work on the machine, hang

the "Do Not Operate" sign on the control rod to

The signs can be obtained from your dealer.

4.Keep work area clean and tidy

(a) Do not throw the hammer or other tools fall on

the work area.Wipe slipping all grease, oil or other

substances likely to cause, to keep the work area

clean and tidy, in order to safely operate.

(b) If you can not keep the work area clean and

tidy, there will be tripped, the risk of slip or fall

and cause injury.

(c) Using of water for cleaning the the top window

manufacturing with plexiglass (polycarbonate), do

not use any alkaline solvent. The spent as benzene,

toluene, methanol, or other alkaline solvents, there

will be a chemical reaction, such as dissolving or

decomposing glass, polycarbonate and aging.

(d) Engine is running, you need two people to

carry out maintenance

5. To prevent injury, when the engine is running,

do not carry out maintenance.If you must operate

the engine running, they have in the case of at

least two people to operate in accordance with the

following provisions:


32

(a) One person must be sitting in the operating

chair and ready to turn off the engine. All

personnel must keep in touch with each other.

(b) Pull the safety lock lever to the locked

position.

(c) Operation close to the fan, the fan belt or other

rotating parts,it has the dangerous of stuck by parts,

so pay special attention.

(d) Do not touch any control lever,if must operate

a lever, send a signal to othe persons,warn them to

move quickly to a safe place.

(e) Do not put tools or other objects to fall into or

insert the fan or the fan belt, otherwise it would be

parts breakage or flying out.

6. The right tools

(a) Only use the right tools and the correct use of

tools.

(b) If use the tool of damaged, inferior, defective,

temporary or improper can cause serious injury.

7. Correct prop machine

(a) Never maintenance the machine in the absence

of support machine .

(b) Before maintenance machine, the working

device should be down to the ground.

(c) If you must lift the machine or device to carry

out maintenance, support the prison machine or

device. Do not use slag bricks, hollow tire or shelf

to support the machine, they will collapse under a

continuous load. Do not work in a machine with a

single jack support.

8. Accumulator

The accumulator red high-pressure nitrogen.When

operating the accumulator, carelessness may cause

explosion ,resulting in serious injury or


33

damage.Therefore, we must observe the following

precautions:

(a) Do not disassemble the accumulator

(b) Do not let the accumulator near fire or to storm

drain in flames.

(c) Do not punch holes, welding or torchin on the

accumulator, .

(d) Do not bump or rolling accumulator or

accumulator subjected to any impact.

(e) When the disposal of the accumulator,you must

be deflated. Please contact withCARTER dealer to

carry out such operations.

9. Welding operations

Must carry out the welding operation by qualified

welders, and equipped with the proper equipment.

When welding, there maybe the risk of fire or

electric shock. Therefore, do not allow unqualified

personnel for welding.

10. Remove the battery terminals

Repair of electrical systems or welding, remove

the negative (-) terminal of the battery to prevent

static electricity.

11.When adjust the track tension by

high-pressure greasing, first of all pay attention to

safety.

(a) Grease is pressed under high pressure into the

track tension adjustment system.

(b) When the adjustment, if there is no compliance

with maintenance procedures, grease drain plug

will fly out and cause serious injury or damage.

(c) when to relax the track tension and release the

grease drain plug, loosen the drain plug not to

exceed one circle, and slowly Loosen the grease

drain plug.


34

(d) Do not make of the face, hands, feet, or body

near the grease drain plug.

12. Do not remove the buffer spring

Buffer spring assembly used to mitigate the impact

of the tension pulley, which includes a

high-pressure spring, so if demolished with error,

spring will fly out, resulting in serious injury or

even death, so do not remove the spring.

13. Compressed air

(a) When cleaning with compressed air, flying

particles may cause personal injury.

(b) When using compressed air to clean the filter

or heat sink, to wear goggles, dust masks, gloves

and other protective equipment.

14. Regular replacement of safety-critical parts

(a) In order to long-term safe operation of the machine, it is necessary to periodically refueling and

maintenance.To further enhance security, hoses, seat belts and other safety-related parts must be

replaced periodically.

(b) Exceeds a predetermined time, the parts of the material will naturally change. Repeated use can

cause deterioration, wear and damage, the result will malfunction and cause serious injury or damage.

When in operation, according to external inspection or touch difficult to judge how long these parts can

be used,therefore must be replaced regularly.

(c) If you find any defects in safety-critical parts, has not yet reached a specified time, you have to

replace or repair.

15. Regular replacement of rubber hose

(a) Due to aging, excessive wear, rubber hose containing flammable liquids may break under pressure.

The aging and wear of the rubber hose, check alone is difficult to judge the extent of its bad. And should

therefore periodically replace the rubber hose.

(b) From time to time to replace the rubber hose may result in fire, liquid injected into the skin or the

device hit around the personnel accident, causing severe burns, gangrene, or other injury.

16.Safely maintenance of air-conditioning systems

(a) Refrigerant spilled on the skin can cause

frostbite, never make the refrigerant touch with the

skin.

(b) The maintenance of the air conditioning

system,with reference to the description of the

refrigerant container, correct use the refrigerant.


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Refrigerant is R134a, can not be used with other

refrigerant, otherwise it will cause damage to the

air conditioning system.

(c) The use of recovery and recycling system to

prevent refrigerant emissions into the atmosphere.

Keep away from the sources of ignition when

maintenance the air-conditioning system .

. R134a refrigerant is non-toxic gas at room temperature, but it will become highly toxic gas when

exposed to an ignition source.

SAFETY－Warning signs and icons

36

1.4 WARNING SIGNS AND ICONS

1.4.1 PRODUCT NAMEPLATE

Product rating plate riveted to the inside of the left platform

The nameplate details of domestic market as the above photo.


37

1.4.2 THE LOCATION OF THE WARNING SIGNS AND ICONS

Marked location map1

1. WARNING! Excavator working range

Do not stay in working ares ,otherwise there is a

risk of rolling.

2.WARNING! Excavator working range

Do not enter the excavator working range,

otherwise, there is a danger of being crushed!


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3.Adjust the elastic of excavator crawler

The elastic adjustment of excavator crawler should

not over one circle, other wise there is the risk of

wounding by regulator valve which flying under

high pressure.

4 .Forward direction of excavator

Warning the forward direction of excavator when

operate the excavator travel lever (pedal) to

forward.

Marked location map 2

5. Diesel tank marked

Alert the user raises different grades Quality

diesel in different ambient temperature !


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6. Hydraulic tank marked

Alert the user to inject the brand, cleanliness of hydraulic oil,and

the volume of the hydraulic tank!

7. Drain direction of oil-water separator marked

The user presses rotation drain valve.

Revolve the oil-water separator according to the marked direction

on the separator.

8. WARNING! Be careful to avoid burns.

9. WARNING! Be careful to accidentally slip and fall;prohibit to

tread on or walking.


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10. WARNING! Be careful to the damage of belt.

11. WARNING! Be careful to the damage of rotating object.

12. Clean the air filter marked

13. Lifting the points of excavator


41

Marked location map3

14. The safety lever locking / Open marked

15. The operating of adjust seat marked.


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16. Lubrication and maintenance marked


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Marked location map 4

17. Read the manual

18. WARNING!Attention to the high-voltage, keep a safe

distance to prevent electric shock danger

19. Warning of leaving the operation seat

Placing the working device to the ground before leaving the

machine, moving the safety leer to the lock position, and then pull

put the engine key.

20. Options of machine operating

21．Emergency exit

STRUCTURE AND TECHNICAL FEATURE－Structure of the whole machine

44

2 STRUCTURE AND TECHNICAL FEATURE

2.1 STRUCTURE OF THE WHOLE MACHINE

The structure of the whole machine and each part’s name is as follows:

1. bucket 2.arm 3. bucket cylinder 4. arm cylinder

5. lift arm 6. lift arm cylinder 7. control handle 8. cabin

9. oil tank 10. hydraulic oil tank 11. clump weight 12. engine

13. pedrail 14. travel motor 15.supporting wheel 16. pedrail wheel

17.pilot wheel 18.mould board 19. revolving dial

PICTURE CT45 STRUCTURE

This machine comprises working system, upper dial and chassis travel system. Working system and upper dial is

connected by turning connector; while upper dial and chassis travel system is connected by rotating bearing

Power installation is a 4 cylinder water cooled diesel engine. It drives a hydraulic pump.

Every action of the excavator is under hydraulic pilot control. The working speed could be adjusted with stepless

shift. The two pilot valves besides the driver's chair control the turning around of the working system and revolving dial.

When a pilot handle lies between two positions，pushing control piston cup could achieve multiple action of the two

parts.

The hydraulic oil which goes through lift arm, arm or bucket cylinder could control the bucket and arm’s action. It

also could control the lift arm and arm’s raising and falling. It could control the working system’s location and pose.

The hydraulic oil which goes through multiple valve and rotary motor could make the motor turning either in


45

forward direction or in reverse direction. The motor drives the turning speed reducer to implement the revolving dial’s

360º turning.

The turning speed reducer is multistage planetary shift. The output shaft of the speed reducer has a gear wheel

which is in gear with annular gear of rotating bearing。The annular gear and outer ring of the rotating bearingare

respectively connected with revolving dial and chassis. The output shaft of the speed reducer make annular gear and

outer ring do relative motion, which leads to the turning around of the revolving dial.

The turning motor is equipped with a valve which supplies oil could prevent air pocket emerging. And it’s also

equipped with mechanical braking system.

The hydraulic oil which goes through multiple valve to left and right travelling motor makes the motor turning in

forward or reverse direction. Then the multistage planetary shift speed reducer drives the two pedrails and makes the

excavator move, reverse and turning. The motor is equipped with balance valve to make sure the machine is not

overspeed.

There is big room and good visual field in the cabin. It could be overturned 30º and easy for maintenance. There is a

handle of safety mechanism for the pilot control system on the left side of the cabin. Before the driver left his chair,

pull up the handle to cut oil source of all the pilot valves.

The travelling speed of this machine is fast to transfer field. But if there is a long distance to go, it could also be

transported by truck.

Warm air blower is optional.

http://www.iciba.com/search?lang=utf-8&s=air+pocket

http://www.iciba.com/search?lang=utf-8&s=visual+field


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PICTURE 2: HYDRAULIC SYSTEM OF CT45

1. hydraulic oil tank 2. input oil filter 3. oil return filter

4. oil cooler 5. hydraulic oil pump 6. pilot oil filter

7. accumulator 8. pilot system safety control valve

9. left pilot vavle 10. subsidiary pilot valve 11. left travelling pilot valve

12. right travelling pilot valve 13. right control pilot valve

14. pilot valve for bulldozing 15 bucket cylinder

16. lift arm cylinder 17. right travelling motor 18. central turning connector

19. left travelling motor 20. arm cylinder 21. travelling solenoid valve

22. cylinder for bulldozing 23. multiple control valve 24. rotary motor

STRUCTURE AND TECHNICAL FEATURE－Structure and dimension

47

2.2 STRUCTURE AND DIMENSION

CT 45

PICTURE3 CT45DIMENSION

Max transportation length(mm) 5560 Length of pedrail(mm) 2190

Width(mm) 1750 Width of prdrail(mm) 300

Height(mm) 2450 Width of mould board(mm) 1650

Min ground clearance(mm) 350 Ground clearance of the revolving dial(mm) 585

Tread(mm) 1710 Turning radius of the revolving dial(mm) 1600

2.3 TECHNICAL FEATURE

2.3.1 OPERATING WEIGHT

with 0.17 cubic meters bucket 4,200 kg

2.3.2 ENGINE

kW/rpm 28/2200

2.3.2a ENGINE

kW/rpm 32/2200（Cummins）

27.1/2200(Yanmar)

STRUCTURE AND TECHNICAL FEATURE－Technical feature

48

2.3.3 RUNNING SYSTEM

speed, high/low (km/h) 4.4/2.7

max traction force(KN) 34.1

grade ability 58%(30º)

There is N220 lubricating oil in the speed reducer.

2.3.4 TURNING SYSTEM

There is N150 lubricating oil in the speed reducer.

Turning speed (rpm) 12.0

2.3.5 HYDRAULIC SYSTEM

displacement of the main pump(cc/min) 20.8+20.8+16.8

pressure(Mpa) 21

displacement of the pilot gear pump(cc/min) 4.9

pressure(Mpa)

2.3.6 ELECTRIC SYSTEM

voltage 24V

accumulator 2×60Ah

Prohibit direct flushing the cab, the electric control box device .When cleaning, use wipe mode.

t

PICTURE 4: CT45 ELECTRIC SYSTEM

http://www.iciba.com/search?lang=utf-8&s=voltage


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1. accumulator 2. main switch 3. starting motor

4. starting relay 5. safety relay 6. generator

7. voltage regulator fuse 8. voltage regulator 9. forewarmer

10 forewarm relay 11. switch starter 12. solenoid valve relay

13. shift relay 14. shift switch 15. shift electromagnet

16. working lamp 17. working lamp relay 18. working lamp fuse

19. working lamp switch 20. horn fuse 21. horn relay

22. horn 23. horn switch 24. wiper assembly fuse

25. wiper assembly switch 26. wiper assembly 27. warm air blower(optional)

28. charging relay 29. voltmeter fuse 30. charging indicator light

31. voltmeter 32. fuel level indication 33. water thermometer of engine

34. pressure gauge of engine mobile oil 35. hydraulic oil temperature gauge

36. engine tachometer 37. warm-up pilot lamp 38. calculagraph

39. gauge 40. lamp and radio fuse 41. lamp switch

42. lamp 43. radio 44. loudhailer

2.3.6A ELECTRIC SYSTEM

voltage 12V

accumulator 2×60Ah

PICTURE4A CT45 ELECTRICAL SYSTEM

http://www.iciba.com/search?lang=utf-8&s=indicator+light

http://www.iciba.com/search?lang=utf-8&s=pilot+lamp

http://www.iciba.com/search?lang=utf-8&s=calculagraph


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1. accumulator 2. main switch 3. starting motor

4. starting relay 5. safety relay 6. generator

7. voltage regulator fuse 8. voltage regulator 9. forewarmer

10. forewarm relay 11. switch starter 12. solenoid valve relay

13. shift relay 14. shift switch 15. shift electromagnet

16. working lamp 17. working lamp relay 18. working lamp fuse

19. working lamp switch 20. horn fuse 21. horn relay

22. horn 23. horn switch 24. wiper assembly fuse

25. wiper assembly switch 26. wiper assembly 27. warm air blower(optional)

28. charging relay 29. voltmeter fuse 30. charging indicator light

31. voltmeter 32. fuel level indication 33. water thermometer of engine

34. pressure gauge of engine mobile oil 35. hydraulic oil temperature gauge

36. engine tachometer 37. warm-up pilot lamp 38. calculagraph

39. gauge 40. lamp and radio fuse 41. lamp switch

42. lamp 43. radio 44. loudhailer

45. fuel cut off valve

2.3.7 SERVICE REFILL CAPACITY

fuel tank 70L

mobile oil of engine 7.0L

hydraulic system (include hose, tank and cylinder) 90L

hydraulic oil tank 80L

travelling speed reducer 2×0.8L

2.3.8 DIGGING PARAMETER

http://www.iciba.com/search?lang=utf-8&s=indicator+light

http://www.iciba.com/search?lang=utf-8&s=pilot+lamp

http://www.iciba.com/search?lang=utf-8&s=calculagraph


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CT 45

max digging height(mm) 5050

max dumping height(mm) 3500

max digging depth(mm) 3700

max digging radius(mm) 5720

max digging radius on ground(mm) 5610

max vertical digging depth(mm) 3200

max breakout force (KN)

bucket 23.7

arm 18.5

PICTURE6 CT45 DIGGING PARAMETER


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2.3.9 DIMENSION OF CYLINDERS

cylinder bore(mm) Pole diameter(mm) stroke(mm)

Lift arm cylinder 90 45 545 915

Arm cylinder 80 45 600 920

Bucket cylinder 70 40 443 745

swing cylinder 80 45 480 875

Bulldozing cylinder 90 45 140 560

2.3.10 BULLDOZING SYSTEM

max scraping depth(mm) 350

max raising height(mm) 250

2.3.11 BUCKET CAPACITY

backhoe bucket(m³) 0.069~0.26

2.3.12 CONTROL SYSTEM

The control system is just as charm 6.

2.3.12.1 ACCELEROGRAPH AND PARKING 10 and 11 in charm 6: Push forward 10 to make the engine run faster. When stopping the machine, pull backward

10 to the end and then pull out parking handle 11.

2.3.12.1 A ACCELEROGRAPH AND PARKING

10 and 11 in charm 6: Push forward 10 to make the engine run faster. When stopping the machine, pull backward

10 to the end and then pull out parking handle 11.

2.3.12.2 WORKING AND TURNING SYSTEM

Just as 2 and 8 in charm 6

Right pilot valve: push forward the handle to put down lift arm, pull backward to raise the lift arm. Push rightward

the handle to achieve eversion of the bucket and push it leftward to make the bucket roll on.

Left pilot valve: push forward the handle to put out arm, pull the handle backward to draw arm back. Push


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rightward the handle to turn the revolving dial right and so it does when push it leftward.

STRUCTURE AND TECHNICAL FEATURE－Control system

54

2.3.12.3 TURNING OF THE WORKING SYSTEM(OPTIONAL)

There is a button on top of the left pilot valve handle. If the button is not being pressed the pilot valve controls the

turning of the revolving dial. But if the button is pressed down then the revolving dial will stand still. Working system

will move in the same direction with the handle.( charm 7)

2.3.12.4 TRAVELLING CONTROL

Just as the charm 7, when push forward the control lever or pedal( ④⑤⑥⑦ in charm 6),the machine will move

forward. When pull backward the machine will reverse. And the machine will stand still when they are in mid

position.

2.3.12.5 CONTROL OF THE BULLDOZING SYSTEM

1. media player

2. left pilot valve

3. subsidiary pilot valve pedal

4. left travelling pilot valve pedal

5. left pilot valve lever

6. right travelling pilot valve lever

7. right travelling pilot valve pedal

8. right pilot valve

9. bulldozing pilot valve

10. engine accelerograph

11. control of the burningout of the engine

12. safety control lever

PICTURE6 CT45CONTROL SYSTEM

left pilot control valve walking control right pilot control valve earthmoving control

http://www.iciba.com/search?lang=utf-8&s=accelerograph


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As 9 shows in PICTURE 6, push forward control lever to let earthmoving blade down, backward to lift it.

2.3.12.6 CONTROL ON ANXILIARY WORKING ATTACHMENTS

As shows in PICTURE 3, control attachments by pedal on the left of walking pedal.

2.3.12.7 SAFETY SYSTEM IN CONTROL

Uplift safety system lever(12 in PICTURE 6) of pilot control on the left side of left control box,; then oil flow is

prevented and the machine working system is stopped for safety. Whereas put down the lever; then oil will flow into

pilot control system and machine will go on working.

2.3.12.7A SAFETY SYSTEM IN CONTROL

Uplift safety system lever(11 in PICTURE 6A) of pilot control on the left side of left control box,; then oil flow is

prevented and the machine working system is stopped for safety. Whereas put down the lever; then oil will flow into

pilot control system and machine will go on working.

1 media player

2 left pilot control valve

3 pedal for auxiliary pilot control valve

4 pedal for left walking pilot control valve

5 lever for left walking pilot control valve

6 lever for right walking pilot control valve

7 pedal for right walking pilot control valve

8 right pilot control valve

9 earthmoving pilot control valve

10 engine accelerator control lever

11safety lever for pilot control

PICTURE 6A CT45 CONTROL SYSTEM.


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2.3.12.8 engine switch

On the instrument panel below right armrest(picture7-1)

Switch shifts are showed in picture 7-1

①”stop”: electricity cut down

②”working”: engine working or electricity switches on

at this position, engine are working smoothly. After engine starting, the key automatically turn to this point

③”start”: turn the key to this position to start engine, meanwhile accelerating fuel flow.

④”pre-heat”: turn the key to this point to preheat engine.

PICTURE 7-1 CT45 ENGINE SWITCH

2.3.12.9INSTRUMENT PANEL (PICTURE 8)

As showed in the picture. It is used for showing temperature of engine water, fuel capacity, working hour, temperature

of hydraulic oil, engine oil pressure

On left of seat is control box , which is fixed

with scraper switch, working lamp switch,

fan switch.


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Light Indicator(in PICTURE 8):

7electrification indicator—when accumulator fails to work, it lights and warning starts.

6warning light indicating temperature of hydraulic oil—when hydraulic oil too hot, it lights and warning starts.

11warning light indicating low oil pressure—when oil pressure below criterion, it lights and warning starts.

10preheating indicator—it lights when preheating engine.

9warning light indicating engine water too hot—when engine water temperature above criterion, it lights and warning

starts.

12 warning light indicating ail filter jam—when ail filter resistance heavy which shows filter needs replacement, it

lights and warning starts.

8 8warning light indicating water full in oil-water separator—when water in oil-water separator too full, that is to say,

water should be let out, it lights and warning starts.

CT45A INSTRUMENT PANEL

1 working hour accumulator

2clock

3fuel position meter

4rotating speed meter

5warning light indicating low fuel

6warning light indicating temperature of hydraulic oil

7electrification indicator

8warning light indicating water full in oil-water separator

9warning light indicating engine water too hot

10preheating indicator

11warning light indicating low oil pressure

12 warning light indicating ail filter jam

13indicator for accumulator voltage or rotating speed

14 temperature meter for engine water or hydraulic oil

2.3.12.10 workbench locking

Accomplish workbench locking by mechanical arrester in rotating reducer

it is necessary when machine is shipped or stopped on slope.

2.3.12.11driver seat

Seat is adjustable to front and back. Flexible upwards or downwards. Both armrest can be turned backwards.

MACHINE OPERATION－Working temperature permitted

58

3 MACHINE OPERATION

3.1 WORKING TEMPERATURE PERMITTED

Hydraulic oil temperature:

Bucket <80℃

Hydraulic rock breaker 80℃-85℃

3.2 ENGINE STARTING

Make sure that all control levers are at medium position.

Examine hydraulic oil in oil tank, reducer lubricant and engine lubricant in place.

Insert key into switch hole to start engine.

Adjust accelerator to make engine working smoothly.

Examine indicator lights.

Check if there is oil(such as lubricant, fuel, hydraulic oil) or water leakage.

⊿ATTENTION PLEASE!

1)when engine works, do not turn the key. Or high voltage electricity will do harm to circuit and electronic parts.

2)when shipping machine, do not start the engine.

3)before practical working, firstly familiar to surroundings aspects, to check if there are blocks there, land carrying

capacity, if there is enough room when machine gets through underground way, bridge, or under electrical cable.

3.3 ENGINE STOPPING

Put bucket and blade down to ground.

After engine working a lot, stop it after 5-12 minute’s rotating, other than at once.

Push accelerator to the end.

Pull choke switch to the end to extinguish engine.

Turn starting key to “0” point (indicator lights die)


Notice for Parking: Turn off general power switch to maintain the battery charge, and discharge the battery regularly.

3.3A ENGINE STOP

Put bucket and blade down to ground.

After engine working a lot, stop it after 5-12 minute’s rotating (at low speed), other than at once.

Push accelerator to the end.

Turn starting key to “0” point (indicator lights die)

3.4 OPERATION TECHNIQUES

Sit down，push safety lever of pilot control system to get hydraulic oil for pilot control valve.

After starting, make engine rotate 1-2 minutes at idle speed, and then try each working part 3-5 times at low engine

speed to check if they are in good conditions.

Accelerate the engine to standard level.

Uplift earthmoving blade and bucket.

Start walking or working.


1)blade is in the front of machine, machine operating should accord to this direction.

MACHINE OPERATION－Operation techniques

59

2)make sure there are none blocks around the machine site

3.4.1 WALKING ON SLOPE OR ON ROUGH ROAD SURFACE

Due to small width, when machine walking up on slope or rough road surface, especially horizontally across slope, be

careful to place working equipment upwards along slope. When walking down, bucket should be placed close to the

ground.


1)when stopping machine on slope, put blade down to ground and insert bucket into earth.

2)horizontally walking on slope where gradient is more than 12°is forbidden. Avoid to turn around on slope.

3.4.2 TRENCHING

Place earthmoving blade in the rear, into earth.

Excavate earth by operating arm cylinder. Adjust bucket angle, or operate bucket cylinder. Do not dig bucket too deeply,

or it will fail to work. When it fails to work, properly uplifting arm. When bucket full, uplifting arm and lifting arm,

letting bucket above ground to discharge.


1)make sure not to touch electrical cable .

2)avoid destroying underground pipelines.

3)when getting an electric shock, do not leave driver seat and keep others away from the machine until machine walks

out and electricity extinguished.

3.4.3 BACKFILL OR GRADING

Drive the machine perpendicular to ditch, cut blade into earth, and push earth into ditch.

3.4.4 BUCKET FITTING

As PICTURE 9 shows,

Operate arm to make its hole and bucket hole in the same line. Then insert steel bar①(diameter:300mm) in.

Uplift lifting arm and arm, making bucket perpendicular to arm.

Operate arm cylinder, making hole of connecting bar and bucket side hole in the same line.

Fix pin ②

Take out steel stick and fix the pin②

That is all.


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PICTURE CT45 BUCKET FITTING

When removing bucket, operate machine contrarily.

3.4.5 TRANSPORTATION

Given two boards, excavator can climb onto truck by itself.

To avoid possible accidents, board angle should be less 15°. Or board slope length should be 3.5 times the board height.

Board width should be 1.2-1.5 times the pedrail width.

Climbing ways:

Drive excavator in line with board slope and let blade in the rear. For safety consideration, drive excavator close to

board, climbing along board slope slowly to the end. Then stop walking, extend arm to let machine decline onto truck

plane, and drive the machine to proper position.

Put down arm, place bucket on the plane, and push down the blade.

When drive excavator out of truck:

Uplift arm and bucket, pull blade up.


61

PICTURE 10 TRANSPORTATION OF CT45

Check there are none blocks within operation range. Turn arm and bucket to the rear board slope.

Drive the machine slowly until to the up end of board, extend the arm to let pedrail down to board, and drive it

smoothly to the fround.


1）whenever uploading or downloading excavator, transportation truck should be strictly fixed. When driving the

machine, must’t operate other working equipment.

2)fixed machine by chocks and rope.

3)after finishing operation, before leaving seat, please pull up safety lever of pilot control system to cut down oil flow,

avoiding possible accidents otherwise.

4 EXAMINATION AND MAINTENANCE

Examine working hour meter to decide maintenance time.

When examine the machine, firstly fix it on ground and extinguish engine.

Every time examining oil position, injecting oil and lubricant, please clean nozzle, cover, and stopper.

⊿repairing should be finished by technicians.

1)electrical system, should be repaired by electrical technicians or according to their guidance.

2)hydraulic system, rotating system and walking system, should be repaired by expert.

3)engine, should be repaired by engine engineers.

4.1 OPERATION AND MAINTENANCE IN WEAR-IN TERM

First 100 working hours is wear-in term. In this term, be careful to operate machine, avoiding heavy load.( for 50 hours

at beginning, only 80% of full load is permitted). Operation in wear-in term affects machine life.

After 50 working hours, should start first maintenance; meanwhile examine pollution level of hydraulic oil(reading

shouldn’t be above NAS9). Otherwise, replace new oil.

When hydraulic system does not works, do not keep engine rotating at high speed.

Begin excavating operation after hydraulic oil temperature goes above 20℃.

Examine and maintain the machine strictly according to table guidance( EXAMINATION AND MAINTENANCE

PERIOD TABLE)

MAINTENANCE－Commone examination

62

5 MAINTENANCE

5.1 COMMONE EXAMINATION

According to the period, examine aspects as follows:

1 leakage by eyeballing(if leakage happens, should examine corresponding circuit oil pressure)

2 elasticity parts, to see if there is nick, break and distortion.

3 appearance of mechanical parts.

4 condition of operation system, control lights and other indicators.

5 emission color and if there is abnormal noise.

5.2 FUEL CIRCUIT

5.2.1 FILLING

▲Fuel tank capacity is 70L.

▲to avoid condensate in fuel, fully fill fuel tank after daily working.

▲injecting hole is in front of fuel-oil tank( upon workbench)(PICTURE 11)

▲examine oil fuel fluid position by fluid position indicator.

▲clear condensate and deposit every 100 hours.

▲pull out stopper(5 in PICTURE 11) to let out condensate and deposit until there is fuel out, and then push the stopper.

5.2.2 TANK CLEARANCE

▲clear fuel tank every 200 hours.

▲pull out stopper to let all fuel out.


63

PICTURE 11: STRUCTURE OF FUEL TANK

▲push the stopper, open air filter cover(1 in PICTURE 11), take out filter net(4 in PICTURE 14).

▲Fill half of fuel tank with fuel through filter. Then let out fuel again. Clean filter net and put it in place.

▲Fix the stopper and fully fill fuel tank.

Let out air in fuel circuit.

5.2.3 FUEL GUSHING PRESSURE EXAMINATION

Do examination every 400 working hours.

Strictly comply with engine operation manual to do examination. Fuel gushing pressure is 19.6MPa. examination

should be finished by engine technicians.

Gushing nozzle decide engine efficiency, so it must be periodically maintained.

Pay attention to following abnormal phenomena which indicate gushing nozzle in bad condition. If necessary, please

consult our service department or engine manufacturer.

▲ strike noise of single cylinder or cylinders.

▲ Engine too hot.

▲ Low working efficiency.

▲ Emission becomes dark.

▲ Fuel consumption increases.

Maybe above phenomena are caused by following aspects:

▲ Air leakage in inlet or outlet.

▲ Fuel spray valve wrongly adjusted.

▲ Fuel filter dirty or destroyed.


64

▲ There is water in fuel.

▲ Air filter dirty or jammed.

5.2.4 AIR OUTLET OF FUEL CIRCUIT

when replacing fuel filter, cutting fuel pipeline, cleaning fuel filter or accidentally emptying fuel tank, air maybe enter

fuel circuit. Then air outlet is necessary before starting engine.

Solutions are as follows:

PICTURE 12 FUEL CIRCUIT OF CT45 ENGINE.

1 examine seal conditions of all circuit joints.

2 loose outlet screw④, and turn hand shank of manual pump on fuel transfer pump. After hand shank rises, push it

down, over and over again, until there is no air pump out around outlet screw. Fix outlet screw, put down hand shank

and turn it tight.

5.2.5 CLEAN OR REPLACE FUEL FILTER ELEMENT

▲ turn loose screw.

▲ loose filter end to take out filter element.

▲ clear filter with clean fuel. Examine filter element, if there is a hole, filter element should be replaced.

▲ fit element again, and pay attention to seal gasket. If necessary, replace it.

▲ clean fuel circuit.


65

5.2.6 CLEAN INLET FILTER NET OF FUEL TRANSFER PUMP

Clean inlet filter net of fuel transfer pump every 50 hours.

There is a fuel transfer pump outside injecting pump. Around inlet joint(⑤ in PICTURE 12) of transfer pump is filter

net for clearing impurity. When cleaning it, remove the joint, take out filter net,clean it with pure fuel and re-install it.

5.2.4A DRAINING AIR IN FUEL CIRCUIT

When replacing new fuel filter, cutting off fuel pipeline, cleaning filter or emptying fuel tank, maybe there is air

coming into circuit. Then air draining is necessary before starting engine, with ways as follows:

1 examine all joints to see if they are still airproof enough.

2 loose draining screw②, rotate refueling pump plunger③ on fuel filter, until there is no air bubble out around draining

screw. Then re-fix the screw.

5.2.5A FILTER REPLACEMENT

Replace fuel filter every 200 working hours or 3 months:

1 remove filter;

PICTURE 12A FUEL CIRCUIT OF CT45

2 clean surface of filter gasket with smooth cloth and throw away O-ring.

3 install new O-ring, injecting filter with clean fuel, and lubricate O-ring with clean oil.

Remarks: In order to reducing possibility of fuel leakage, be sure to fix filter properly. Too tight fitting will do harm

to filter itself. Please accord to engine operation manual exactly.

5.2.6A OIL-WATER SEPERATOR

Every day drain the water and deposit in separator.

MACHINE OPERATION－Cooling circuit system

66

Extra separator for the machine guarantees fuel purity.

5.3 COOLING CIRCUIT SYSTEM

5.3.1 EXAMINATION OF COOLANT

Before engine starting, examine if there is enough coolant in water radiator. Fully fill it with water when necessary.

5.3.2 EXAMINATION OF TRANSFER TUBE AND HOOP

Before engine starting, examine tubes and hoops.

5.3.3 CLEANING RADIATOR CORE

Clean it every 400 working hours.

Dust on radiator core surface will affect heat radiating and should be cleaned timely.

Water or high-pressure air are both acceptable . However, high-pressure water or air maybe destroy radiator core. So

muzzle should be placed more than 500mm far away from core surface.

5.3.4 COOLANT REPLACEMENT

Radiator capacity is 8L. Replacement should be done after first 50 working hours. Later every half of one year,

separately in spring and in autumn.

1 remove radiator cover (① in PICTURE 13)

2 turn the cock to let coolant out.

3 clean up cooling circuit system. Firstly shut cock, fill radiator with full water or lotion, rotate engine for 10 minutes,

and then cease engine and let out water or lotion.

4 refill radiator with coolant, rotating engine at idle speed for some minutes to cover whole circuit with coolant.

5 examine surface of coolant and supplement until full.

PICTURE 13 RADIATOR OF CT45

MACHINE OPERATION－Hydraulic system

67

5.3.5 COOLANT

Coolant is mixture of water, antifreeze and antiseptic. When temperature below 0℃, antifreeze is

necessary for coolant according to antifreeze manufacturer’s guidance.

Coolant water should be soft water, tap water or bottled water.

If you can not make sure if it is soft water, you can wash your hand with it. If it is soft water, there will be bubble.

Antifreeze feature of coolant: -20℃ for temperate zone; -30℃ for frigid zone.

Before winter, must examine concentration of coolant and test its antifreezing ability.

In torrid zone with temperature above +35℃, too hot engine will reduce coolant conductibility. In this case, coolant

should be water; meanwhile add aseptic to avoid erosion and lime deposit.

Aseptic for water is 0.101L.

Attention please!

1 when coolant has consists of antifreeze, aseptic is unnecessary. Coolant with -20℃ antifreezing ability is 5.7L.

2 when working temperature below -20℃, antifreeze proportion should be increased.

3 do not pour water and antifreeze into radiator before their complete mixture in another vessel.

4 be careful that antifreeze is poisonous.

5 when antifreeze into eye, must clean eye with pure water firstly, then sending the sick to hospital.

6 storage of antifreeze and coolant should accord to all product instructions.

5.4 HYDRAULIC SYSTEM

5.4.1 PRE-HEATING OF HYDRAULIC OIL

Working temperature of hydraulic oil should be 50℃-70℃. When temperature below 20℃, hydraulic parts will be

destroyed. So before working, preheat hydraulic oil until 20℃ when oil temperature below this degree.

Preheating:

1 Rotate engine for 5 minutes at idle speed≧700rpm.

2 keep accelerator pedal at middle position for 5-10 minutes.

3 at this speed, extend and shrink every cylinder several times and operate rotating motor and walking motor to preheat

them. When oil temperature above 20℃, operation can begins. When necessary, extend or shrink cylinder to the end

point, and preheat oil under full load. But time should not more than 30 seconds once. Repeat this operation over and

over again until oil temperature comes above 20℃.

5.4.2 EXAMINE SURFACE OF HYDRAULIC OIL

Examine surface of hydraulic oil every 10 hours:

1 stop excavator at flat ground.

2 start engine and ,and move each cylinder up and down

3 shrink arm cylinder and extend bucket cylinder. Then place bucket on the ground, blade down and extinguish the

engine.

4 fluid surface of hydraulic oil should be at middle position of oil meter. If necessary, supplement it.

5.4.3 CLEAR WATER AND IMPURITY IN HYDRAULIC OIL TANK

Do the clearance every 2000 working hours.

1 stop the engine until oil temperature comes down or before daily working, clear air in hydraulic oil tank.


68

▲Loosen the bolt at the bottom of the oil tanker slowly to let the oil out.( see the pic 18,part 6)

▲Let the water and the impurity out until you see the clear hydraulic oil out and then tight the bolt.

▲Fill up the oil tank when the oil is not enough.

5.4.4 RENEW THE HYDRAULIC OIL AND CLEAN THE OIL FILTER

Do it per 2000 work hours if the capability of the hydraulic tanker is 80L.

Note:

1).For preventing the operator from being scalded, operating only in the condition of the hydraulic oil is cool or at the

time before working.

2).Make sure do not let the water or impurity into the oil tanker when renew the oil.

5.4.4.1 Following these items to renew the hydraulic oil.

▲Park the excavator on the flat ground.

▲Loosen the cap of the air cleaner (see the pic 18,part8)，depress the air press in the oil tanker.

▲Remove the filter element of the air filter. (see the pic 18,part8)

▲Prepare a container more than 80L .Let out the oil through the air filter by oil pump.

▲Loosen the bolt at the bottom of the oil tanker to let the oil out entirety. . .

▲Remove the oil input pump assemble (see the pic 18 part 4), and then remove the oil filter. (See the pic 18,Part 1) .

▲Clean the inside of the oil tanker completely.

▲Clean the bolt at the bottom of the oil tanker and then fix it.

▲Clean the oil filter, checking the O seal ring in the oil filter.( see pic 18,part 2).

▲Check the O seal ring in the the oil input pump assemble, fix the oil filter on the oil input pump assemble. Then

install the assemble on the oil tanker.

▲ Add the oil through the oil filler of the air filter. The oil should be meet the specification (see the oil list, and the

cleanliness should be no more than NAS6 grade.)The oil level should be achieve to the middle level of the oil

gage.

5.4.4.2 Follow these items when change the hydraulic oil. Vent the air in the hydraulic system.

5.4.4.2.1 Vent the air in the pump.

▲Loose the oil drain plug screw R1,fill the hydraulic oil to the hydraulic fluid connection then fix up the plug. Start the

diesel engine Let the cylinders and motors run 5 times at the speed of 1000rpm.Then let the diesel run 8 minutes

without load.

▲Turn the screw slowly, let the air in the pump out. Then tight the screw in 65NM moment of force..

5.4.4.2.2 Vent the air in the hydraulic hose

▲At the low speed of the engine, simulate the excavating works for 15 minutes .Repeat every cylinder and rotary

motor. Let the air in the hydraulic system out.

▲Make the machine in the horizontal position and check the hydraulic level. Complete the hydraulic oil if possible.

5.4. 5 RENEW THE FILTER ELEMENT OF THE BACK OIL FILTER

The structure is as the picture 18.Renew every 1000 hours.


69

The back oil filter is in the hydraulic tank, so operate as follow:

▲Loose the air filter by key, reduce the air pressure in the oil tank.

The return oil filter is in the hydraulic oil tank, so:

▲Loose the air filter (8) by key and let the air press down in the oil tank.

▲Loose the bolt out. (7)

▲Remove the flange of the oil filler (9) and the seal (11).

▲Remove the parts of the return oil filter from the return oil flange (17).

▲Remove the filter element (13) from the haulm (12).

▲Renew the filter element and O-ring (14),assemble with the haulm (12),and then paint the hydraulic oil on the O-ring,

and then assemble them and they should match the flange.

▲Fix up the seal (11).

▲Fix up the flange (9),note: The boss on the lower surface of the flange should be press in the hole on the haulm (12)

where the spring in and then tight the bolt.(17)

▲Fix up the air filter.

PICTURE18:.HYDRAULIC OIL TANKER OF CT45

5.4.6 CHANGE THE OIL FILTER ELEMENT OF THE PILOT CONTROL

SYSTEM

Change it every 1000 hours .See the picture 19.


70

PICTURE19 OIL FILTER OF THE PILOT CONTROL CT45

Note: Make sure you discharge the air in the hydraulic oil tank.

▲Screwing our the shell of the oil filter.(22)

▲Remove the filter element. (20)

▲Fix a new O-ring on the filter element.

▲Before installation of the filter element, you should paint the hydraulic oil on the surface of the oil

filter.

▲Clean the shell of the oil filter(22) and soft magnet. Do not let the booty or dust into the shell of the oil

filter.

▲Tight the shell of the oil filter and the end of the oil filter at the moment 25-35N·M.

▲Connect the hose and start the engine at low speed, keep the engine run 3 minute to eliminate the air in

the system.

▲Let the machine park in the level ground and check the oil level after stop the engine. Supply the oil if

necessary.

5.4.7 THE PRECAUTIONS WHEN USE THE HYDRAULIC HARMER

There will be more pollution and cauterize of the hydraulic system. The change cycle of the oil filter should be short to

prevent the damage of the hydraulic parts. The change cycle can be refer the follow table.

This table shows the change cycle adjust the all time work of the bucket and hydraulic harmer. The

change cycle should be adjust according the work time of the bucket and hydraulic hammer when they

are not work all the time.

5.4.8 CHECK THE PRESSURE

Hydraulic oil

Oil filter

Assembling bucket

2000

1000

Assembling hydraulic

harmer

1000 500

MACHINE OPERATION－Engine

71

Take a check every 400 hours.

▲Take the check and adjust the pressure when the engine archives the normal temperature.

▲Use the pressure gauge with flexible hose to measure the pressure. The range of the press gauge is 0-30Mpa.

▲Screw out the cap of the connector of the oil output hose on the plunger pump. Connect with the press gauge.

▲Screw out the cap of the connector of the oil output hose on the gear pump. Connect with the press gauge.

▲Check the safe valve setting value of the main circuit.

The press of the hydraulic system should be 21Mpa+-0.2Mpa.If the press can not reach this value,

adjust the safety valve on the control valve until it reaches the specified value。

▲Screw out the cap of the oil out, connect with the gauge. Check the setting value of the prior circuit

safety valve. The press should be 4Mpa+-0.2Mpa. If the press can not reach this value, adjust the safety

valve on the prior circuit safety valve until it reaches the specified value.

Note: If the press of the main circuit and the prior oil circuit can not reach the specified value, you should

inform our agency to adjust.

5.5 ENGINE

5.5.1 CHECK THE LEVEL OF THE ENGINE OIL

The circuit of the engine oil is as the pic21.Check the engine oil level when use the new engine and then should check

once a day.

▲Park the machine on the level ground and stop the engine.

▲Open the shell of the engine, take out the oil leveler, oil line should at the lowest and the highest sign.

▲You can fill the oil from the filler to make sure the level of the engine oil at the specified value if

necessary.

5.5.2 RENEW THE ENGINE OIL

The capacity of the oil tanker is 7 L. Engine oil should be renew after 50 work hours, and then renew it every 100 work

hours, you can refer the picture 21,

▲Park the machine on the level ground and stop the engine. Let the oil out at the high temperature.

▲Loosen the bolt at the bottom of the oil tanker and let all the oil out of the tanker.

▲Clean the bolt and fix it up. Renew the oil patch if necessary. .

▲Open the cover of the oil filler..

▲Fill the new engine oil until the oil lever reach the oil leveler “A”.

▲Fix the cover up and let the engine run for 5 min at low speed.

▲10-20minutes after stop the engine, check the level of the engine oil. fill it if necessarily.

5.5.3 CLEAN AND RENEW THE FILTER ELEMENT OF THE OIL FILTER

The first time for clean the oil filter is after working 50 hours for the new machine ,then clean the filter element with

the clean diesel oil every 100 work hours.

▲Loose and screw out the filter element, clean or renew it.

▲Start the engine, check the leak tightness of the oil filter element. The warning light of the oil press should be off. If

not, take a check.

▲Stop the engine, check the oil level of the engine oil. Supply the oil if necessary.


72

5.5.4 CHECK TENSION OF FAN BELT

Take the first check after 50 work hours. Check every 100 work hours every 100 work hours.

▲Make sure correctly tension of fan belt to ensure the use life of engine and fan. According to the picture 21A-5, for

the proper tension of belt between the fan belt pulley and engine belt pulley, press it with thumb at the middle of belt to

ensure proper 10-20mm. loose the bolt of engine can adjust it.

▲Replace in the condition of damaged belt.

5.5.1A CHECK THE LEVEL OF THE ENGINE OIL

The engine oil circuit as the picture 21A. The new machine should have a check first, check every day in the future.

▲Park the machine on the level ground, stop the engine.

▲Open the engine hood; check the oil level of the engine oil. Supply the oil if necessary.

5.5 2A REPLACE ENGINE OIL

The contains of oil is 7 liters, the first replace is after working 50 hours for the new machine with working 200 hours

once in the future. As picture 21, use CH-4(or CF-4) with high quality of 15W-40 more viscosity machine oil, such as

Cummins Premium Blue or the same kind of Cummins engine, choose proper oil according to the maintenance of

engine under weather conditions. ▲Leave excavator on level, take out of oil at the warm of engine stopped.

▲Loose bolt to leak all oil

▲Clean the bolt and reassemble, replace combination cushion

▲Open the cover of oil filling.

▲Refill the oil until the oil level up to max sigh of oil ruler “A”


73

▲Cover the oil filling, start the engine and let it run at low speed for 5 min.

▲After engine stop 10- 20 mins, check the oil level. Reinforce if necessary.

5.5.3A REPLACE OIL FILTER

The first time for cleaning the oil filter is after working 50 hours for the new machine with working 200 hours

once in the future.

▲Dismantle the oil filter, clean the area around of filter in tidy and smooth cloth and the surface of gasket. please

ensure to dismantle O ring which may exhibited on the filter.

▲Add thin oil on the surface of gasket before assembling new filter.

▲Start the engine and check the assembling of oil filter. Check whether the press light on instrument board is quenched.

If not, check reasons.

▲Stop the engine and check the oil level. Reinforce if necessary.

Attention:

Excess tight of filter will result in screw thread distortion or damage the leak tightness of fuel filter, so please do that

according to the maintenance.

5.5 4A CHECK DRIVE BELT AND TENSION OF FAN BELT

Check that everyday strictly according to the maintenance manual.

▲Make sure correctly tension of fan belt to ensure the use life of engine and fan. According to the picture 21A-5, for

the proper tension of belt between the fan belt pulley and engine belt pulley, press it in 10kg at the middle of belt to

ensure proper 10mm. loose the bolt of engine can adjust it.

▲Replace in the condition of damaged belt.

PICTURE21A ENGINE OIL CIRCUIT OF CT45

5.5.5 CHECK FIXING OF THE ENGINE

The fixing configuration of the engine as Picture 22


74

PICTURE22 FIXING OF THE ENGINE

Note:

The first examination must be carried out in 50 hours after the new machine starting. Then it will be carried out every

100 hours. The tight torque of bolt ①, ②, ③ is all 70N.M.

5.5.6 OTHER OPERATION OF ENGINE

Gap examination and adjustment for air valves: the gap of the air valves in cold clean criticality is 0.25-0.30mm. It

must be examined every 100 working hours.

Examine the tight torque of cylinder head bolts, which is 118-137N.M, it must be examined every 100 working hours.

Examine the working status of starter and generator.

Examine the speed scope of engine. The idling highest speed is 2300-2350r/m.

Note: all the examination must be carried out by engine servicing professional strictly according to the engine

instruction.

5.5.6A OTHER OPERATION OF ENGINE

Gap examination and adjustment for air valves: the gap of the air valves in cold clean criticality is 0.30mm. It must be

examined every 200 working hours.

Examine the working status of starter and generator.

Examine the speed scope of engine. The idling highest speed is 2350-2400r/m.

Note: all the examination must be carried out by engine servicing professional strictly according to the engine

instruction.

5.6 AIR FILTER

5.6.1 CLEAN THE REAR LID

The air passage of the engine is as picture 2.3.

This must be carried out every 10 working hours:

▲Screw off the rear lid ①.

▲Clear dust in the lid.

▲Examine the seal ring disabled or not.

MACHINE OPERATION－Air filter

75

▲Examine the inner hull of the filter. Don’t permit any foreign matter into inner filter.

▲Remount the rear lid. Pay attention to let dust exhaust vent downward.

5.6.2 CLEAR OR CHANGE THE FILTER ELEMENT IN THE AIR FILTER

This must be carried out every 100 working hours.

▲Take off the rear lid.

▲Take out seal ring.

▲Take out the air filter 3, brash away dust on the surface of the filter with a hairbrush, and blow with dry constringent

air. The pressure of constringent air should not be bigger than 0.588MP. the distance from constringent air exit to filter

wall is about 30mm, and when clearing, please let constringent air blows from inner filter to outside (as picture 23).

▲Please change the filter after maintenance for 6 times.

Note: 1. Don’t flap the filter with something hard or clear it with water or oil.

2. Under bad working condition, please shorten the maintenance period properly.

5.6.3 CLEAR ALL PARTS IN THE FILTER

▲Before remounting filter, please check up the seal ring(2) and filter. Change it if disabled.

▲Way to distinguish disabled from normal: you can set lamp-house in the filter. If there is hole, please change the

filter.

PICTRURE23 CT45

5.6.4 CHANGE AIR FILTER ELEMENT

Please change the filter element after clearing it for two times.

▲Act as clearing process.

MACHINE OPERATION－Storate battery

76

▲Examine the quality of new filter element by shining.

▲Before install new filter element, clean all elements inside of the filter.

▲Install new filter element.

▲Install the rear lid.

5.7 STORATE BATTERY

5.7.1 EXAMINE THE LIQUID LEVEL OF THE ELECTROLYTE

Examine it every 50 hours.

▲Clean Storage battery, in case impurity trespass electrode.

▲Prohibit direct flushing battery, clean wiping method.

▲Put off the blanking cover. The liquid level should be between 10-15mm above polar plate.

▲To reach the liquid level, only distilled water is allowed.

▲Metal tundish is forbidden.

5.7.2 EXAMINE ACID AND CHARGE STATUS

Examine this every 400 hours.

▲The acid content under 20 degree centigrade should be 1.28g/cm3 for the storage battery in correct charge status.

▲To make sure of good working condition for the starter of the engine, the battery should be in charge status. Used in

cold area, the battery should be stopped to ice up.

▲The current intensity for charge should be 1/10 of battery content. That is to use 6A current to charge in 2-5 hours

continuate charge time (to charge for 2 hours when electro hydraulic proportion is 1.16, 3 hours when electro hydraulic

proportion is 1.1; the lower of proportion, the longer of charge time). Then use 50% of above numerical value charge

current to continue to charge for 15 hours. If the electro hydraulic proportion of 6 monomer is all between 1.24-1.29,

charge is over.

▲To make sure of the connection of battery and cable, please fix them well and daub the electrode with acidproof

Vaseline.

Note: fixing not enough or too will damage the battery. Forbid battery near to blaze in case of danger for blast.

5.8 WALING SPEED REDUCER

Soon after the machine walks, the oil in the speed reducer will heat. When examining or maintaining, you must wait for

oil cooling. Loosen the exhaust plug 2 or 3 loop to release air pressure in the box. Then put off the plug. It is dangerous

to put it off quickly.

▲Travel notice : To avoid the travel motor destroyed abnormally, it is prohibited that the machine travel more than

2km one time ,and stop machine for cooling after travel 15 minutes continuously .

5.8.1 EXAMINE LUBE LEVEL IN EACH SPEED REDUCER

Examine this every 200 hours.(picture 24)

▲The excavator lies on level ground.

▲Circumrotate the walking reducer, and let the two plugs to the position as picture. Then stop the machine.

▲After oil cools, open up plug ① slowly to release the air pressure in the box. Then screw off the plug with 12-15N.M

MACHINE OPERATION－Waling speed reducer

77

moment.

▲Open up plug ②, and examine the oil level. The level should reach to the lower margin of the plug.

▲If necessary, oil can be refilled (act as refilling operation process below).

▲Clean plug ②, remount it to the speed reducer with screw moment 12-15N·m.

5.8.2 CHANGE LUBE

Change lube every 800 hours for each reduction gearbox (as picture 24).

▲Lie the excavator on level ground.

▲Circumrotate the reducer to the position as picture.

▲Let off the reducer oil when it is in hot status.

Note: not be scalded by hot oil.

PICTURE24 CT45 LUBRICATION FOR WALKING REDUCER

▲Loosen plug ③ to let off oil, and loosen plug ②to let oil out.

▲Clean plug ③, remount it to the speed reducer with screw moment 12-15N·m.

▲Refill stated lube from oil hole ①, until oil flow out from oil level examining hole②.

▲Screw ①and ② with screw moment 12-15N·m.

5.8.3 EXAMINE FIXING OF THE REDUCER

The first examination should be carried out in 50 working hours and then once for every 400 working hours. The screw

moment of bolt for connection of reducer and underframe, driving wheel should be 130N·m.

5.9 GYRE SPEED REDUCER

Gyre speed reducer depends on leaking oil from starter to lubricate.

MACHINE OPERATION－Pedrail

78

5.10 PEDRAIL

5.10.1 EXAMINE AND ADJUST TENSIONING OF THE PEDRAIL

Tensioning should be examined every 10 working hours as picture 25.

▲Lie excavator on hard level ground.

▲Make the mould board back, and make all piston rod of mould cylinder put out until the pedrail put up a little.

▲Let the bucket against ground. The operation lift arm cylinder makes head of excavator up.

▲Strain the pedrail correctly, and make a 10-15mm clearancebetween supporting wheel and pedrail (as picture 25).

▲Put off the cover cap ① on every truck frame (as picture 26), and refill inlet on tensioning setting comes out.

▲To relax the pedrail, loosen tie-in ③ (as picture 26), and let lubricating grease flow out, until reach correct

tensioning.

▲To strain the pedrail, put the tie-in of grease gun (provided as tools with complete machine) connecting with tie-in ②

(as picture 26). Then refill with grease gun until strain the pedrail correctly.

5.11 SUPPORTING WHEEL, PEDRAIL WHEEL AND PILOT WHEEL

5.11.1 EXAMING FIXING MOMENT OF SUPPORTING WHEEL

The structure of walking system is as picture 27. The first examination must be carried out in 50 hours. After that once

will be every 400 hours.

The fixing moment of bolt ① is 130N·m.

5.11.2 THE OIL LEVEL OF SUPPORTING WHEEL, PEDRAIL WHEEL AND

PILOT WHEEL

It must be carried out every 800 hours.

▲Take out the plug ②,③,④ respectively from the supporting wheel, pedrail wheel and pilot wheel.

▲Refill in the wheels with oil can.

▲When oil flows from oil hole, screw down plug ②, ③, ④ again.

MACHINE OPERATION－Lubricate

79

PIC25 CT45 CORRECT TENSIONING OF WALKING ORGANIZATION AND TENSIONING SETTING OF

WALKING ORGANIZATION

PICTURE CT45 STRUCTURE OF WALKING SYSTEM

5.12 LUBRICATE

Lay the bucket on the ground.

Lay the earth-push board on the ground

MACHINE OPERATION－Lubricate

80

Turn off the engine

Make the oil nipple clean

Notice: the oil nipple in locate in the picture 2.8

PICTURE28 OIL NIPPLE FO THE CT45

1. The connect point between the bucket and the arm

2. The nipple of the top of the bucket

3. The connect point between the bucket and the rocker

4. The connect point between the arm the rocker

5. The bucket oil cylinder nipple point

6. The arm and the boom connecting point

7. The top of the arm

8. The bottom of the arm

9. The top of the arm cylinder

10. The connecting point between the boom and the base

11. The bottom of the arm cylinder

12. The lubricating oil channel of the turning support

13. The channel of the turning support

14. The connecting point between the earth pushing board and the bottom

15. The bottom point of the oil cylinder

16. The top point of the oil cylinder

17. The connecting point between the earth push board and the bottom frame

MACHINE OPERATION－Check and maintenance table

81

5.13 CHECK AND MAINTENANCE TABLE

No. Content of check and

maintenance

Maintenance periods(working hours)

days 50 100 200 400 800

1 2 3 4 5 6 7 8

1

General

check

The leak of the oil, water, fuel Y

The appearance of parts and

the hose

Y

The operating parts and the

light

Y

The diesel Y

The bolt and the connecting Y

2

the loop

of the

fuel

Check the oil and fill Y

Drain the water and impurity Y

Clean the oil tank Y

Check the pressure of the oil Y

Clean or change the filter Y

Clean the oil filter Y

3

the loop

of the

water

Check the hose and hoop Y

Check the cooling water Y

Change the cooling oil Y

Clean the radiator Y

Check the consistency of the oil Y

4

the loop

of the

hydraulic

system

Check the oil Y

Drain the water and impurity Y

Change the oil, clean the filter Y

Change the filter Y

Check the pressure Y

5

engine

Check the fuel Y

Change the oil Y

Clean or change the filter Y

Check the strain of the fan strap Y

Check the adjust of the air door Y

Check the cylinder Y

Check the engine Y

MACHINE OPERATION－Check and maintenance table

82

6

air filter

Clean the dust Y

Clean or change the oil filter Y

7

storage

battery

Check the electrolyte Y

Check the acidity Y

8

running

motor

Check the oil lever Y

Change the oil Y

Check the connecting bolt Y

9

pedrail

Check the strain Y

10

the wheel

supporting

weight/steer

Check the support wheel Y

Check the oil lever Y

11

lubricate

Add lubrication for all nipple Y

5.14 OIL SELECTING

Lubrication and fuel temperature viscidity commend

1 2 3 4

Lubrication

used for

engine

40CD winter

summer

10.5－11.5cSt when

it’s 100 degree

SAE15W 40CD

30CD SAE15W 30CD

Hydraulic

system

YB-N6R -20 to 40

degree

61.2 － 74.8cSt

when it’s 40 degree

Running

motor

N200 all 220cst when it’s 40

degree

ISOVG220

All wheel HZ-23 all 20-25cst when it’s

50 degree

General

lubrication

Lithium

lubrication

DIN51*25

K-P2K

fuel summer >0 degree 0 light fuel

winter -15 to 0 degree -10 light fuel

-25 to 0 degree -20 light fuel

MACHINE OPERATION－Long term store

83

5.15 LONG TERM STORE

▲ Drain the oil when it’s is warm, then fill with the preservative oil. The piston engine is MIL-L21260

type. When store in winter use SAE10W, when it’s summer use SAE30W.

▲ Should add the same type preservative oil to the tank, then mix well.

▲ Check the antifreeze, add the antifreeze make it at least -20 degree. If there is no preservative in the

antifreeze, add it. According to the MIL-G43390, the 5% preservative needed.

▲ Start the engine, let it working at least 15 minutes when it’s no loading.

When drain the oil of the hydraulic system and the reducing motor, it should working for a long time,

then change the oil.

▲ Block out the air inlet and outlet pipe with the plastic paper and the adhesive tape.

▲ Disassemble the storage battery, recharge it, leave on the ground dry.

▲ Clean the machine, leave on the ground dry.

According to the climate, this method can store the machine for a year. But after 6 months, should let it

work for 15 minutes without loading. Then add lubrication for everywhere.

When rework after long term store, check every part. Then drain all the oil stay in the pipe.

MACHINE OPERATION－Malfunction and solving

84

5.16 MALFUNCTION AND SOLVING

malfunction Reason solve

The engine

can’t start or

difficult to

start

Something wrong with the starting motor Change or repair the engine

Low battery Recharge or change the battery

warm-up or its circuitry unmerited Repair the warm-up block

Oil spout time is wrong Check the spout time

The hose block Clean the oil circle

Oil filter block Clean or change the filter

Air/water/dust in the oil pipe Drain the air/water

Spout nipple dusty or low pressure Repair it

Something wrong with Spout pump Ask the agent

Not enough oil Fill oil

Air Inlet an outlet block Clean the hose

Engine

shock/work

irregular/down

Oil filter block Clean the oil filter

Air/water in the oil system Repair it

Oil hose block, spout nipple dusty Drain the air, clean the oil circle

High pressure hose demage Change the hose

Fuel not enough Fill the oil

Cant’ adjust the accelerator Ask the agent

Spout nipple damage Ask the agent

Spout pump not in time or the nipple block Check the time and the nipple

The power of

the engine too

low

Air in the fuel Drain the air

Oil support blocked Clean it

Spout oil time not correct Adjust the time

Spout nipple work incorrect Check the pressure

Air filter block Clean the filter

Air inlet and outlet incorrect Adjust it

The cylinder cushion broken Change the cushion

Spout pump incorrect Ask the agent

Engine too hot Check the radiator, the block, the

strain of the strap

The engine is

too hot

The radiator oil is not enough Add it

Temperature sensor incorrect Change a new one

The air filter block Clean it

The strap of the fan to loose Change to strain it

Radiator dusted Clean it

Thermometer incorrect Change it

Bad oil or to much oil Change the oil

Oil pressure

too low

Too less oil Add it

The oil filter block Clean it


85

malfunction reason solve

Oil pressure

too low

oil leaking in the pipeline tight it and change immediately

too high temperature of cooling water adopt correct proportion of mixture

coolant or consult to the local agent

Ashy and

black smoke

from the

engine

bad quality of fuel use proper fuel

blocking of air filter replace filter elements

oil of spurt not on time adjust in term of rules

bad nozzle inspect and replace part

White smoke

from the

engine

bad fuel use proper fuel

too much oil in the engine resume oil position recommended

oil of spurt not on time adjust in term of rules

water in the fuel in the cylinder inspect and replace fuel

Unable

electrification

the joint becomes not crowded or rustness clean or tight

the belt of engine not crowded or with

problems

tight or replace

unable electrification of electrical machine turn to local agent

Engine not

working or

working

slowly

the joint becomes not crowded or rustness clean or tight

not enough electrification replace

wire damaged turn to local agent

Engine

working while

no

electrification

in electrical

machine

problems with engine turn to local agent

ruined wire inspect or replace

safety wire ruined replace

problems of inductor replace

bulb ruined replace

No effect on

transmission

in the tread

problem of switch replace

wire damaged replace

problem of speed conversion value replace

Slow reaction

of hydraulic

system

cooling of hydraulic oil adopt measures to warm that

pilot system with low pressure adjust in term of rules

wrong useness of hydraulic oil use correct hydraulic oil

low speed of engine turn to local agent company

Low

temperature

of hydraulic

oil

cooling of hydraulic oil adopt measures to warm that

pilot system with low pressure adjust in term of rules

wrong useness of hydraulic oil use correct hydraulic oil

low speed of engine turn to local agent

Too high of

hydraulic oil

wrong useness of hydraulic oil use proper hydraulic oil

blocking of oil turn to local agent company

blocking of hydraulic filter clean or replace

abrasion of oil pump turn to local agent company

oil radiator blocking clean coolant

problems of oil radiator turn to local agent company


86

safety value or steering system and excess

flow value with high pressure

turn to local agent company

malfunction reason solve

too dirty oil release oil and refill oil

hydraulic oil

emulsification

or with foam

pipeline from oil box to oil pump leaking air inspect and tight

wrong hydraulic oil use proper hydraulic

water in the hydraulic oil replace oil

low oil surface adjust oil surface

oil pressures

problem

hydraulic pump damaged replace the pump

lack of oil in the system refill oil

safety value problem turn to local agent company

all the parts

can not work

hydraulic pump damaged turn to local agent company

noisy in the

oil pump

noisy

unchanged in

oil

lack of hydraulic oil refill oil

oil suction pipe leaking air inspect or replace

assistant pump damaged replace

hydraulic safety equipment in unnormal

working

inspect and mend

cylinders and

motors not in

working

oil pump damaged turn to local agent company

main safety value with low pressure readjust pressure

low surface of oil in oil box refill oil

oil suction filter blocking clean filter

oil seal damaged inspect or replace

inspect or replace inspect or replace

pilot value trouble replace

pilot value repture or leaking oil inspect or replace

tread

equipment not

in working

equipment damaged turn to local agent company

pilot value not in working replace

pilot value repture or leaking oil inspect or replace

two tread

equipment not

in working

central steering joint concatenation oil turn to local agent company

Unnormal

treadment

too tight or too release for pedrail readjustment

low performance of oil pump turn to local agent company

pallet pedrail metamorphose inspect or replace

stone in pedrail links mending

control value leaking oil turn to local agent company

low performance of motor turn to local agent company

steering

unnormal

low oil pump performance turn to local agent company

steering motor damaged turn to local agent company

pilot value not in working turn to local agent company

no continue

steering

steering gear damaged turn to local agent company

steering sustain damaged turn to local agent company

lack of lipin turn to local agent company


87

control value oil leaking turn to local agent company

Inspection and maintenance table:

S/N

CONTENT OF MAINTENANCE

Maintenance term(hours)

Work day 50 100 200 400 800

3 4 5 6 7 8

1 generally

inspect

▲oil and water leaking ▲

▲parts and soft pipe appearance ▲

▲fixed bolt and hydraulic joint ▲

▲management parts, working

light and power light

▲

▲working information of diesel

engine

▲

2 fuel loop ▲inspect oil position and

reinforce

▲

▲eliminate condensate and

impurity

▲

▲clean oil tank ▲

▲inspect spray pressure ▲

▲replace filter element ▲

3 cooling

water

loop

▲check rubber soft pipe and

housing

▲

▲inspect cooling water position ▲

▲clean radiator lamina ▲

▲replace cooling liquid △ ※

▲inspect consistence of cooling

liquid

▲

4 hydraulic

loop

▲inspect hydraulic oil

position(reinforce if necessary)

▲

▲eliminate water and feculence

in oil tank

▲

▲replace hydraulic oil , clean oil

filter

▲

▲replace hydraulic loop and

pilot oil loop filter element

▲

▲check pressure ▲

5 engine check oil position and

surface( reinforce if necessary)

▲

replace oil △ ▲

replace oil filter element △ ▲

check fan-belt tension ▲

check the adjustment of value ▲

check the fixation of the engine △ ▲


88

S/N

CONTENT OF MAINTENANCE

Maintenance term(hours)

Work day 50 100 200 400 800

3 4 5 6 7 8

6 air filter clean rear lid ▲

clean or replace air filter

element

▲

7 accumulator electrolyte oil level ▲

check acidity and charging

state

▲ ※

8 speed

reduction

driver

check oil level ▲

replace oil ▲

check joint bolt moment △ ▲

9 pedrail check the tension of the pedrail ▲

10 supporting

wheel,

chain wheel

and induct

steering

wheel

check supporting wheel

moment

△ ▲

check their oil position ▲

11 lubricate digging equipment, bulldoze

equipment, deflexion

equipment and gyrus

equipment

▲

5.14A OPTIONAL FUEL LIST

The following oil plants must be adopted as rules:

lubricating oil or fuel temperature viscidity optional oil recommended

Lubricate used in engines :

High Quality SAE15W-40

CH-4

High quality SAEW-30 CH-4

Temperature

More than -10ºC

in the whole year

-25ºC to 10ºC

High quality

SAE15W-40 CH-4

High quality

SAEW-30 CH-4

Hydraulic system: YB-N68 -20ºC to 40ºC 61.2-74.8centistoke

.in 40ºC

Speed reduction drive: N200 Any temperature 220 centistoke in

40ºC

ISOYG220

Supporting wheel, Guider

roller, Chain wheel:,

Wheel oil HZ-23

Any temperature 20-25 centistoke in

50C

Common lubricating oil:

lithium grease I

DIN51825 lithium

grease or at the base

of K-P2K lithium


89

grease III

Fuel:

0# light diesel oil in summer

-10#or-20# diesel oil in winter

>0ºC for 0#

-15º-0ºC for -10#

-25ºC-0ºC for -20#

Attachment: introduction of media player

1. power switch and sound control knob

turn to the right of knob is for open the power. Go on with it will be make sound louder. Opposite is the

same.

2. sound control knob:

the same as the first step

3. getting tape knob:

press the knob and the tape will be out

4. tape loading:

push the tape into that door

attention: at leisure please keep the tape out prevent from abrasion the wheels of tapes.

5. skip toward and backward knob:

press the skip toward key, it will skip toward while press the backward key, it will skip backward.

6. balance control knob:

control the sound of left and right voice.

7. scan knob:

searching for the programs in the radio

8. AM and FM knob:

9. working power:

show tape working and its direction.

CONTENTS · 1.1.1 RECOGNIZE SAFETY LABEL (a) This is the label of “safety”. ... Please follow...

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Transcript of CONTENTS · 1.1.1 RECOGNIZE SAFETY LABEL (a) This is the label of “safety”. ... Please follow...