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WCM CTX8010 Operating Manual

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CTX8010 EXCAVATOR
OPERATING MANUAL
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Summary of Contents for WCM CTX8010

  • Page 1 CTX8010 EXCAVATOR OPERATING MANUAL...
  • Page 2 Chapter I: Usage Features and Performance Parameters of CTX8010 Excavator Section I: Usage and Features The CTX8010 Excavator is a versatile machine, capable of multiple tasks such as excavating, • crushing, ditch cleaning, drilling. With quick-hitched attachments, the machine's utilization is significantly enhanced, offering •...
  • Page 3 Section IV: Basic Structure of Hydraulic System An in-depth look at the hydraulic components of the CTX8010 Excavator, detailing the • hydraulic cylinders, pumps, and valves. This section will also explain the fluid power mechanism that drives the machine's movement and performance.
  • Page 4 Medium repair: Hydraulic and engine checks. Overhaul: Complete inspections and replacements of major components after a specified number of operating hours. Chapter VII: Troubleshooting of CTX8010 Excavator Section I: General This section covers general troubleshooting procedures for diagnosing issues with the •...
  • Page 5 1. Pre-Operational Checks ✅ Inspect the Excavator Check hydraulic lines, cylinders, and hoses for leaks or damage. • Ensure all safety guards and covers are in place. • Confirm that the tracks or wheels are free of obstructions and properly tensioned. •...
  • Page 6 Keep loads as low as possible when transporting materials. • Avoid side-loading the bucket—always lift directly in front of the machine. • ✅ Working on Slopes Move up and down slopes in a straight line—never diagonally. • Keep the boom and arm low when working on an incline. •...
  • Page 7 Adhere to Occupational Safety and Health (OSHA) and other local construction regulations. • Only licensed or trained operators should use the CTX 8010. • ✅ Regular Maintenance & Inspections Perform scheduled maintenance as per the manufacturer’s guidelines. • Keep a logbook of inspections and repairs. •...
  • Page 8 It can be equipped with various attachments, such as a quick hitch, log grab, ripper, levelling bucket, auger, and narrow bucket.
  • Page 9 Quick hitch Narrow bucket Log grab Mechanical thumb Auger Ripper Rake...
  • Page 10 Section II Main performance parameters...
  • Page 11 Overall dimensions Unit: mm A Wheel track 1282 B Overall length of track 377.5 C Ground clearance of platform 843.5 D Ground clearance of platform tail E Chassis width 161.12 F Crawler width 330.53 H Crawler height 2796.48 I Transportation length 1155 J Overall height Work range...
  • Page 12 1-1. Mounted on the rotary table are the regular full-swing type hydraulic excavators, main components of drive system, swing mechanism and auxiliary devices, which are referred to as upper rotary. Therefore, a CTX8010 Excavator is divided into work equipment, upper rotary and drive mechanism.
  • Page 13 Section II: Work Principle of Excavators The work principle of the CTX8010 Excavator involves a sequence of energy transformations that enable the machine to perform various tasks: 1. Diesel Engine Power: The diesel engine converts the chemical energy of diesel fuel into mechanical energy.
  • Page 14 Thus, the excavator operates as an efficient system of energy transformation, where the diesel engine powers the hydraulic system, and the hydraulic system, in turn, drives the various mechanical components of the machine. The movement and power transmission route of the excavator are as follows: 1.
  • Page 15 The sprockets on the CTX8010 Excavator are castings and located at the rear part of the machine, which helps reduce the tensioner part and minimizes track abrasion, wear, and power consumption.
  • Page 16 1.1 Bucket 1.1.1 Basic Requirements 1. The shape of the bucket is designed to facilitate the smooth flow of material while minimizing loading resistance, allowing the bucket to fill efficiently. 2. Bucket teeth are mounted to enhance the linear pressure exerted by the bucket onto the material.
  • Page 18 Chapter III: Service Technologies of CTX8010 Excavator The CTX8010 Excavator operates under high temperatures and pressures, with hydraulic oil temperatures reaching up to 85°C, engine silencer temperatures up to 700°C, and pressures between 16-18 MPa. For safety and efficiency, operators must be specially trained, obtain the necessary certifications, and thoroughly understand the contents of this manual prior to operation.
  • Page 19 Preheating of the Machine on Cold Days: If the weather is cold, the engine may be difficult to start, and the fuel and hydraulic oil may become more viscous. When hydraulic oil is below 25°C, the hydraulic system may operate sluggishly, which could lead to accidents.
  • Page 20 2. Drive Use the drive handles. (1) Straight Forwards or backward move the handle, running the machine forwards or backwards. (2) 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. Left turn with left track as axis: forward move the right handle Right turn with right track as axis: forward move the left handle 3.
  • Page 22 2.2 Swing arm movement 1. Place your foot on the right assist pedal and step forward the swing arm will turn right. 2. Place your foot on the right assist pedal and step back, the swing arm will turn to the left. Expandable track Press and hold the right joystick button, place your foot on the left assist pedal and step forward, the chassis expands outwards...
  • Page 23 Basic Excavation 1. Excavating with Maximum Force: Before beginning excavation, set the arm cylinder at a 90° angle to the arm, and position the • bucket to make a 30° angle with the ground to be excavated. This positioning allows the cylinders to generate maximum excavation force.
  • Page 24 Ditching is carried out in 7 steps, as shown in the figure above. This process outlines the • sequential approach to digging and shaping ditches effectively.
  • Page 25 Section IV: Operational Precautions To ensure safety and efficiency, please observe the following instructions and recommendations: 1. Terrain Awareness: Be cautious of landslides, ground movement, and falling debris, including rocks and loose materials. 2. Collision Prevention: Avoid driving or striking the bucket against other construction equipment.
  • Page 26 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 27 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 28 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 Pivots of bucket and equipment pins connecting rod ★ Others: ★ 2. Lubrication of slewing bearing 3.
  • Page 29 Expandable track ● ● Others Pivot between boom and arm; pivot of arm cylinder plunger; pivot at base of bucket cylinder. Rotation bearing - every 100h 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 30 3. External meshing gear 45 of slewing bearing ---- every 500h 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 31 B. Engine oil Interval (h) Parts Quantity 1000 2000 ● ▲ ★ Engine oil ● ▲ ★ Engine oil filter According to the temperature range during the interval, select the viscosity of oil listed in the table below: Recommended engine oil brand: 15W—40 engine oil...
  • Page 32 Inspection of engine oil level ―――-each day Change of engine oil ―――every 500 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 33 Inspection and Maintenance of Hydraulic System ⚠ Caution: The hydraulic system can become extremely hot during operation. Always allow the machine to cool down before performing any inspection or maintenance. 1. General Safety Precautions Ensure the machine is parked on a flat and solid surface before conducting maintenance. •...
  • Page 34 I. Inspection of hydraulic oil level --- each day Important : With no hydraulic oil, never start up engine! Park machine on the flat ground. Completely retract the arm cylinder and extend out the bucket cylinder, so as to locate the machine. Lower the bucket onto the ground.
  • Page 35 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 36 22. Lower the bucket onto the ground. 23. Turn off the engine. Unplug the ignition key.
  • Page 37 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 38 Please use the genuine Hydraform 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 39 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. ★ ★...
  • Page 40 Inspection of Diesel filter ---every 200h Diesel filter ① is used to separate the water or sediment from fuel. Ensure the quality of diesel fuel entering the diesel engine and prolong the service life of the diesel engine When the working time of the diesel filter element is up and it needs to be replaced, please change a new diesel filter ①.
  • Page 41 Electrical system - Battery Check the battery electrolyte level and the terminals. • Battery Safety, Maintenance, and Replacement ⚠ Caution: Battery Safety The gas inside the battery is highly explosive—keep sparks, flames, and smoking materials • away. Use a flashlight instead of an open flame to check the electrolyte level. •...
  • Page 42 The system uses a 12V battery with a grounded negative (-) pole. • If the battery fails to hold a charge, replace it with a battery of the same model and specifications. • 2. Fuse Replacement If an electrical device is not functioning, check the fuse first. •...
  • Page 43 Check the bolts and nuts for ★ — ˜ tightening torque Note: ★ Maintenance interval under normal conditions ˜ Maintenance needed at the first inspection ø Contact dealers or Rhinoceros. Check the bucket teeth --- each day Check if the bucket teeth is worn or loosened. Worn beyond the service limit, the bucket teeth may be replaced.
  • Page 44 Bucket Replacement Procedure ⚠ Caution: Metal scraps may fly out during pin removal, causing serious injury. • Always wear goggles, safety glasses, or other appropriate protective equipment. • 1. Preparation 1. Park the machine on flat, stable ground. 2. Lower the flat surface of the bucket onto the ground to prevent movement after pin removal. 2.
  • Page 45 11. Start the engine and run it at low speed. 12. Slowly rotate the bucket in both directions to check for any movement interference. 13. If any interference is detected, stop the machine immediately and correct the issue before operation.
  • Page 46 Check the bolts and nuts for tightening torque ……every 250 h (initially at 50 h) Check the tightness at initial 50h and then every 250 h. Tighten it to the set torque if needed. Replace it with bolts and nuts with same or higher grade. Important: please use the torque wrench to check the torques of bolts and nuts! Metric bolts and nuts Thread dimensions...
  • Page 47 Maintenance under the special cases Operational conditions Precautions for maintenance Before operation, check all the drain plugs are tightened up. soft land, wet and rainy 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 48 Machine Storage Guidelines 1. Maintenance Before Storage Inspect and repair or replace any worn or damaged parts. • Clean the primary air filter elements. • If possible, fully retract all hydraulic cylinders. If not, grease all exposed plungers to prevent •...
  • Page 49 Daily Inspections • Short-Term Maintenance • Medium-Term Maintenance • Long-Term Maintenance • Regular and proper maintenance will significantly extend the machine’s service life and efficiency. Section II Troubleshooting of mechanism system Symptom Possible causes How to solve The loose fasteners make noise. Inspect and tighten Noisy structural components Aggravated...
  • Page 50 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 Drive motor is damaged Change The upper and lower chambers of swivel Change the oil seal or clean the...
  • Page 51 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 52 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 53 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 drive of all working devices. Principle diagram 1.
  • Page 54 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 55 Section V: Troubleshooting the Diesel Engine 1. Engine Fails to Start Symptoms: The starter turns the engine, but the engine does not start. • Possible Causes & Solutions: 1. Low battery: The battery may have drained due to electrical appliances left on overnight. Charge the battery properly while the machine is in use.
  • Page 56 If all fuel-related components function correctly, inspect the engine for faults. 3. Hard-to-Start Engine Symptoms: The starter runs correctly but struggles to start the engine. • The engine is difficult to start in cold or hot conditions. • Possible Causes & Solutions: 1.
  • Page 57 Securely tighten battery connections. 3. Loose battery ground wire: Check and repair the ground wire connection. 4. Faulty start circuit: Inspect and repair wiring to ensure proper power delivery to the starter. 5. Faulty starter relay: Test the relay for proper function; replace if necessary. 6.
  • Page 58 CTX 8010 EXCAVATOR - DAILY SAFETY CHECKLIST �� Date: ____________ �� Operator Name: ____________ �� Machine Serial Number: ____________ ✅ 1. Pre-Start Inspection ☐ Check for leaks (engine oil, hydraulic fluid, coolant). ☐ Inspect hydraulic hoses and connections for wear or damage. ☐...
  • Page 59 ✅ 5. Safe Operation Practices ☐ Clear work area of unauthorized personnel. ☐ Avoid sudden movements and excessive speeds. ☐ Keep bucket load within capacity limits. ☐ Avoid working near trenches, edges, or slopes. ☐ Always face downhill when operating on a slope. ☐...