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WCM CTX8010C Operations & Parts Manual

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CTX8010C MINI EXCAVATOR
OPERATION & PARTS MANUAL
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Summary of Contents for WCM CTX8010C

  • Page 1 CTX8010C MINI EXCAVATOR OPERATION & PARTS MANUAL...
  • Page 2 Preface Chapter I Usage Features and Performance Parameters of CTX8010 Excavator Section I Usage and features Section II Main performance parameters Chapter II Basic Structures and Work principle of CTX8010 Excavator Section I Overview Section II Work principle Section III Basic structure of mechanical system Section IV Basic structure of hydraulic system Chapter III Service Technologies of CTX8010 Excavator Section I Basic construction knowledge...

  • Page 3: Section I Usage And Features

    Chapter I Usage Features and Performance Parameters of CTX8010 Excavator Section I Usage and features CTX8010 Excavator are provided with excavating, crushing, ditch cleaning, drilling and bulldozing, with their attachments quick hitched and thus its utilization up greatly. In addition, they are easy to operate and transport and flexible to work at narrow site.
  • Page 4 Quick hitch Narrow bucket Log grab Mechanical thumb Auger Ripper Rake...

  • Page 5: Section Ii Main Performance Parameters

    Section II Main performance parameters...
  • Page 6 Overall dimensions Unit: mm Wheel track 1090 Overall length of track Ground clearance of platform Chassis width Crawler width 2176 Overall height 3247 Overall length 1050 Overall width Work range Unit: mm 1948 Max. Digging depth 2925 Max. Dumping Depth 2703 Max.
  • Page 7 Chapter II Basic Structures and Work Principle of CTX8010 Excavator Section I Overview on CTX8010 Excavator CTX8010 Excavator is composed of power train, work equipment, swing mechanism, control mechanism, drive system, traveling mechanism and auxiliary equipment, as shown in fig. 1-1. Mounted on the rotary table are the regular full-swing type hydraulic excavators, main components of drive system, swing mechanism and auxiliary devices, which are referred to as upper rotary.
  • Page 8 Section II Work principle of excavators Diesel engine changes the chemical energy of diesel into mechanical energy that is then altered with hydraulic gear pump to hydraulic energy that is distributed to each actuating element (such as hydraulic cylinder, swing motor and traveling motor).
  • Page 9 —— distributor valve —— electromagnetic valve —— swing arm cylinder —— The swing arm being to move Arm power route: diesel engine —— coupler —— hydraulic pump (mechanical energy changed to hydraulic energy) —— distributor valve —— arm cylinder (hydraulic energy changed to mechanical energy) —— arm movement Bucket power route: diesel engine ——coupler ——...

  • Page 10: Section Iii Basic Structure Of Ctx8010 Excavator Mechanical System

    Section III Basic structure of CTX8010 Excavator mechanical system 1 Power system CTX8010 Excavator is equipped with three-cylinder air-cooling diesel engine. 2 Drive system CTX8010 Excavator's drive system could transfer the output power from diesel engine through the hydraulic system to work equipment, swing mechanism and traveling mechanism. 3 Swing mechanism Swing mechanism could turn the work equipment and upper rotary leftwards and rightwards, so as to do the excavating and the unloading.
  • Page 11 5.2 Bucket 5.2.1 Basic requirements The longitudinal profile of bucket meets the law of motion of various materials inside of bucket, facilitating the material flow and minimizing the loading resistance and thus fulfilling the bucket. Bucket teeth are mounted to increase the linear specific pressure of bucket onto material, with unit cutting resistance relatively low and easing to cut in and break soil.
  • Page 12 Hydraulic system structure of CTX8010 Excavator I. Rotary motor Rate of flux(LPM) Rotate speed (RPM) Pressure(Bar) Torque(Nm) continu Discontin continu Discontin continu Discontin continu Discontin uity uity uity uity...
  • Page 13 Main pump...
  • Page 14 Traveling motor Disc Valve Motors---6000 series -005 and -006 Drive, Main Geroler Screw, Cap Screw, Cap Item No.5--Part No Item No.6--Part No Item No.6--Part No Item No.6--Part No Displacement /Length /Width /Length /Length /r(in Part No mm(inch) Part No mm(inch) Part No mm(inch) Part No...

  • Page 15: Section Iv Schematics Of Main Valve

    Section IV Schematics of main valve...

  • Page 16: Section V. Electrical System Diagram

    Section V. Electrical system diagram...

  • Page 17: Section Ii Preparation For Work

    Chapter III Service Technologies of CTX8010 Excavator Being of high temperature and pressure, the CTX8010 Excavator could have the hydraulic oil temperature as high as 85℃, the engine silencer temperature as high as 700℃ and pressure as high as 16-18MPa. Therefore, the operators should be specially trained to obtain the proper certificates and to be familiar with the contents in this manual before the operations.
  • Page 18 When hydraulic oil is less than 25℃, it is needed to preheat the machine before any work; otherwise machine may not respond or react very quickly, leading to severe accident. Therefore it is needed to preheat machine if it is cold: ①.
  • Page 19 1.2 Change the high and low speed buttons to rabbit, the machine will move at high speed, and to turtle the machine will move at slow speed (3) Steering A. Left turn in situ: backward shift the left handle and meanwhile forward push the right handle. Right turn in situ: backward shift right handle and meanwhile forward push the left handle.
  • Page 20 3. Excavation 1.4 Push the control handle downward to release the pilot lock. 1.5 The excavator slewing and the work equipment are respectively controlled with two handles, with positions shown below...
  • Page 22 2.2 Swing arm movement 1. Press and hold the swing arm button, place your foot on the assist pedal and step forward the swing arm will turn right. 2. Press and hold the swing arm button, place your foot on the assist pedal and step back, the swing arm will turn to the left.
  • Page 23 2.1 Lower excavation Keep the angle between bucket base and the bevel at 30°, and retract the arm to start work. 2.2 Upper excavation Keep the bucket blade vertical to the ground, and retract the arm to start work. 2.3 Ditching is carried out in 7 steps, as shown in figure.

  • Page 24: Section Iv Operational Precautions

    Section IV Operational Precautions Prohibitions and precautions for hydraulic excavators Avoid the landsliding and the stone falling. Avoid any striking of work equipment. Avoid the bucket from colliding with other vehicle body, the loaded bucket crossing over other vehicle cab or persons.

  • Page 25: Section I Daily Inspection And Maintenance

    Chapter VI Maintenance of CTX8010 Excavator Section I Daily inspection and maintenance Interval (h) Item Quantity Remark Check the engine oil level in sump ★ Check the hydraulic oil level in hydraulic oil tank ★ Check the fuel level in tank ★...
  • Page 26 Section II Periods of overhaul, medium and minor repair Interval (h) Item Quantity Remark 1000 1500 2000 2500 4000 Greasing of slewing ★ bearing Greasing of slewing ★ bearing gears Change the engine oil ● ▲ ★ Change the hydraulic △...
  • Page 27 Technical maintenance A Grease Interval (h) Parts Quantity 1000 2000 Pivot at base of boom Pivot at base of boom 1. Lubrication cylinder ★ of work equipment Pivots of bucket and connecting rod pins Others: ★ 2. Lubrication of slewing bearing ★...
  • Page 28 Expandable track ● ● Others Pivot between boom and arm; pivot of arm cylinder plunger; pivot at base of bucket cylinder. Slewing bearing - every 250h Park machine on the flat ground. Lower the bucket onto ground. Idle engine at low speed for 5min. Turn the ignition switch to OFF and then take off the key.
  • Page 29 Lower the bucket onto the ground Turn off the engine. Park machine on the flat ground. Lower the bucket onto ground. Idle engine at low speed for 5min. Turn the ignition switch to OFF and then take off the key. The grease has to be stored on the top of external meshing gear of slewing bearing, free of any pollution.
  • Page 30 B. Engine oil Interval (h) Parts Quantity 1000 2000 ● Engine oil ▲ ★ ● Engine oil filter ▲ ★ According to the temperature range during the interval, select the viscosity of oil listed in the table below: Recommended engine oil brand: Select the appropriate engine oil viscosity based on the ambient temperature and use the SAE Service.
  • Page 31 Inspection of engine oil level ―――-each day Change of engine oil ―――every 250 h Change the engine oil filter ―――every 500 h Start up engine to preheat up engine oil properly. Park the vehicle on the flat ground. Lower the bucket onto the ground. Idle engine at low speed for 5min.
  • Page 32 Inspection and maintenance of hydraulic system Caution : in work, the hydraulic system may become very hot. Please cool the machine down before inspection or maintenance! Before maintenance of hydraulic system, make sure the machine stands on flat and solid ground. Lower the bucket onto ground and shut down engine.
  • Page 33 I. Inspection of hydraulic oil level --- each day Important : With no hydraulic oil, never start up engine! Park machine on the flat ground. Completely retract the arm cylinder and extend out the bucket cylinder, so as to locate themachine. Lower the bucket onto the ground.
  • Page 34 III. IV. Change the hydraulic oil ---2000 h Replace the hydraulic oil suction filter element ----every 1000 h Caution: do not do so until the hydraulic oil cools down as it may be very hot. Park machine on the flat ground. Completely retract the arm cylinder and extend out the bucket cylinder, so as to locate the machine.
  • Page 35 22. Lower the bucket onto the ground. 23. Turn off the engine. Unplug the ignition key.
  • Page 36 24. Check the hydraulic oil level in hydraulic oil tank and add it if needed. . V. Inspection of hose and pipeline --- Each day ---every 250 h Caution: any sprayed fluid could penetrate your skin, leading to personal casualty! Therefore, use a paperboard to check for leakage.
  • Page 37 Please use the genuine Haihong excavator parts Interval (h) Check points Abnormal Measures Replace it Hose surface Leakage 1 Replace it Every day Hose end Leakage 2 Tighten or replace the Connector body Leakage 3 hose or O-ring Crack 4 Replace it Hose surface Crack 5...
  • Page 38 Fuel system capacity of fuel tank: 7L Interval (h) Parts Quantity 1000 2000 Drain dirt out of collector of fuel ★ tank Check the Diesel filter ★ Change the Diesel filter ★ Leakage ★ ★ Check the fuel hose. Crack / twist / others ★...
  • Page 39 engine to check whether the seal is intact. If the oil leaks, it should be removed and reinstalled. Caution: after the draining, make sure air is drained out of fuel system to make sure the engine could start up normally. Electrical system - battery Check the battery electrolyte level and the terminals.
  • Page 40 Use the proper measures to assist battery start up. If touched with acid: Rinse the skin Use the soda or the lime to neutralize the acid. Rinse eyes for 10 - l5 min and then go to doctor. Caution: Always firstly disconnect the battery clips (-) away from the ground and then lastly connect it. Always keep the terminals at top to battery and the breather clean, to avoid the battery from discharging.
  • Page 41 Replace the battery There is a 12V battery with one negative pole (-) grounded. If battery cannot be charged or store any electricity, replace the battery with same model. Replace the fuse. If the electrical device does not work, please firstly check the fuse. Important: please install the fuse with correct amperage, so as to prevent against burning of electrical system due to overloading! Others...
  • Page 42 Caution: care must be taken to avoid the metal scrap from flying out, leading to personal injury. Wear the goggles or the safe glasses or safe devices suitable for operations! Change the bucket Caution: while hitting out or into the connecting pin, care must be taken to prevent against any personal injury due to out-flied metal scrap.
  • Page 43 Check the bolts and nuts for tightening torque ……every 250 h (initially at 50 h) Check the tightness at initial 50h and then every 250 h. Tighten it to the set torque if needed. Replace it with bolts and nuts with same or higher grade. Important: please use the torque wrench to check the torques of bolts and nuts! Metric bolts and nuts...

  • Page 44: Operational Conditions

    Maintenance under the special cases Operational conditions Precautions for maintenance Before operation, check all the drain plugs are tightened up. Moor land, rainy or snowy After operation, clean machine and check bolts and nuts for break, damage, looseness or loss. Lubricate all parts to be lubricated on time. Before operation, check all the drain plugs are tightened up.

  • Page 45: Chapter Xii Troubleshooting

    Chapter XII Troubleshooting Section I General To ensure excellent performance of Haihongexcavator, all components and parts are of high quality. Machine’s performance and service life are determined not only by manufacturing quality and assembling quality, but also maintenance quality. The marketing representative and service engineer shall remind the user that preventive maintenance is the easiest and most economical one among various ways of maintenance.
  • Page 46 Symptom Possible causes How to solve The main pump supplying fuel to unilateral Change crawler is damaged. The main valve rod is stuck and the spring is Repair or change broken The unilateral crawler fails to move Traveling motor is damaged Change The upper and lower chambers of swivel Change the oil seal or clean the...
  • Page 47 Symptom Possible causes How to solve The sealing component of central rotation Change the sealing component connector is aged and damaged. The left and right crawlers are of different Adjust tightening. Boom (bucket rod and Main valve core is stuck or valve rod spring bucket) move to one Repair or change breaks.
  • Page 48 Symptom Possible causes How to solve other abnormalities) Rotary valve rod on main valve is stuck. Repair Rotary motor is damaged Repair or change The rotation support is damaged. Change The right and left rotation of multiway valve Adjust Indifferent left and right is of different overloaded pressure rotation speed (no other Rotation valve rod of multiway valve is...
  • Page 49 Section IV Troubleshooting of electrical control system Fault codes of electrical control system of excavator The engine fails to start The engine flames out during operation The engine fails to flame out Automatic slow-down does not work Slewing and traveling of all working devices. Principle diagram 1.
  • Page 50 Possible causes Standard value in regular condition and reference value of fault diagnosis Unlocked 1MΩ Between 105 and Locked Below 1Ω ★Turn the start switch of engine to OFF as preparation and keep it at OFF during diagnosis. If all PS, GND, signals and engine start input are correct while engine start output is abnormal, the engine starter relay fails.
  • Page 51 Section V Troubleshooting of diesel engine Symptoms of failed startup of engine: When starting the engine, the starter drives the engine but the engine fails to be started. Possible causes: (1) Low battery; (2) Battery terminal is rusted or loose; (3) Battery earth wire is rusted or loose or poor GND of engine;...
  • Page 52 (5) Inspect and repair the engine. Only when the engine works well can the start-up fail never or seldom happen. Check if it is hard to start the engine Symptom: (1) Starter runs at correct rpm and drives the engine; however, it is hard to start the engine. (2) It is hard to start the engine when it is cold.
  • Page 53 (4) Start circuit is disabled. (5) Electromagnetic relay armature is adherent; (6) Starter fault (7) Driving gear of starter is stuck by engine flywheel gear ring; (8) Driving gear of starter adheres to the bearing. (9) The starter fails to drive the engine; (10) Engine fault;...

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