SUNWARD SWL Series User manual

Operation and
Maintenance Manual
SWL SERIES SKID STEER LOADER

SWL Series Skid Steer Loader
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TABLE OF CONTENTS
1INTRODUCTION ....................................................................................................................................... 5
1.1 MODELS AVAILABLE...................................................................................................................... 5
1.2 ABOUT THIS MANUAL.................................................................................................................... 5
1.3 TREATMENT OF THIS MANUAL.................................................................................................... 5
1.4 UNITS.................................................................................................................................................. 5
1.5 DEFINITION OF “LEFT” SIDE AND “RIGHT” SIDE ...................................................................... 5
1.6 PRECONDITION TO USE THE MACHINE...................................................................................... 6
1.7 SIGNALS................................................................................................................................................ 6
2SECURITY.................................................................................................................................................. 8
2.1 MEANING OF THE SAFETY SIGNS ................................................................................................ 8
2.1.1GENERAL SIGNS .............................................................................................................................. 8
2.1.2 ACOUSTIC SIGNS.......................................................................................................................... 10
2.2 LOCATION OF THE SAFETY LABELS ......................................................................................... 11
2.3 GENERAL PREVENTION ............................................................................................................... 11
2.3.1 GENERAL SAFETY RULES.................................................................................................... 11
2.3.2 CLOTHING AND PERSONAL PROTECTION....................................................................... 11
2.3.3 ENTER AND LEAVE THE MACHINE ................................................................................... 12
2.3.4 PREVENTION OF FIRE TO FUEL AND OIL......................................................................... 13
2.3.5 PREVENTION OF BURNS....................................................................................................... 13
2.3.6 PREVENTION OF DAMAGE OF WORKING EQUIPMENT ................................................ 14
2.4 PREVENTIONS DURING OPERATING......................................................................................... 14
Machine allowable circumstance condition............................................................................................... 14
2.4.1 SAFETY CHECK BEFORE WORKING.................................................................................. 14
2.4.1.1 CHECK THE WORKING SITE.....................................................................................................................14
2.4.1.2 CHECK THE MACHINE...............................................................................................................................14
2.4.2 STARTING THE ENGINE........................................................................................................ 15
2.4.3 MOVING THE MACHINE ....................................................................................................... 15
2.4.3.1 MOVING ON SLOPES..................................................................................................................................16
2.4.3.2 MOVING ON UNUSUAL SURFACES ........................................................................................................16
2.4.3.3 PARKING THE MACHINE...........................................................................................................................16
2.4.4 PREVENTION OF ELECTRIC SHOCK................................................................................... 17
2.4.5 LIMITS OF THE MACHINE .................................................................................................... 17
2.4.6 TRANSPORTATION................................................................................................................. 18
2.5 MAINTENANCE PREVENTION..................................................................................................... 18
2.5.1 GENERAL RULES.................................................................................................................... 18
2.5.2 RUNNING THE ENGINE DURING THE MAINTENANCE.................................................. 19
2.5.3 WORKING UNDER THE WORKING EQUIPMENT AND MACHINE................................ 19
2.5.4 SAFETY RULES FOR HIGH-PRESSURE OIL AND HOSE .................................................. 19
2.5.5 PREVENTION ON THE STARTER AND ALTERNATOR.................................................... 20
2.5.6 PREVENTION OF BATTERY HAZARD................................................................................ 20
2.5.7 PRECAUTION DURING INFLATING THE TIRES ............................................................... 21
3GENERAL DESCRIPTION OF THE MACHINE ................................................................................... 22
3.1 DESCRIPTION OF THE MACHINE................................................................................................ 22
3.1.1 FRONT VIEW............................................................................................................................ 22
3.1.2 REAR VIEW.............................................................................................................................. 22
3.1.3 MACHINE DISTRIBUTION..................................................................................................... 23
3.2 SPECIFICATION .............................................................................................................................. 24
3.2.1 GENERAL DATA ..................................................................................................................... 24
3.2.2 OVERALL DIMENSION .......................................................................................................... 25
3.2.3 ENGINE ..................................................................................................................................... 27
3.2.4 ELECTRIC SYSTEM ................................................................................................................ 27
3.3 MACHINE IDENTIFICATION ........................................................................................................ 28
3.3.1 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN) 28
3.3.2 MACHINE SERIAL NUMBER................................................................................................. 28
3.3.3 ENGINE IDENTIFICATION PLATE....................................................................................... 29
3.3.4 SERIAL NUMBER OF CHASSIS
............................................................................................. 29
3.4 SECURITY DEVICES....................................................................................................................... 29

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3.4.1 RESTRAIN BAR ....................................................................................................................... 29
3.4.2 BOOM LOCKS.......................................................................................................................... 30
3.4.3 RADIATOR OVERTURNING PROTECTION LOCK ............................................................ 30
3.4.4 RETAINER OF AUXILIARY CONTROL PEDAL.................................................................. 30
3.4.5 CABIN OVERTURNING PROTECTION LOCK .................................................................... 30
3.4.6 SEAT.......................................................................................................................................... 30
3.5 INSTRUMENTS................................................................................................................................ 32
3.6 JOYSTICKS....................................................................................................................................... 35
3.7 SWITCHES AND BUTTONS........................................................................................................... 37
3.8 CABIN ............................................................................................................................................... 39
3.9 REAR WINDOW............................................................................................................................... 39
3.10 SEAT BELT....................................................................................................................................... 39
3.10.1 FASTEN THE SEAT BELT...........................................................................................................................39
3.10.2 UNDO THE SEAT BELT ..............................................................................................................................39
3.11 AUTO-LEVELLING SYSTEM......................................................................................................... 40
3.12 FLOATATION SYSTEM.................................................................................................................. 40
3.13 FUSES................................................................................................................................................ 40
3.14 RELAYS ............................................................................................................................................ 42
3.15 DOCUMENTS CASE........................................................................................................................ 42
3.16 ENGINE HOOD................................................................................................................................. 42
3.17 REAR COVER................................................................................................................................... 43
3.18 BATTERY ......................................................................................................................................... 43
4OPERATION OF THE MACHINE .......................................................................................................... 43
4.1 RUNNING-IN.................................................................................................................................... 43
4.2 CHECKS BEFORE OPERATION..................................................................................................... 43
4.3 STARTING THE ENGINE................................................................................................................ 44
4.3.1 NORMAL STARTING .............................................................................................................. 44
4.3.2 STARTING THE ENGINE IN COLD WEATHER .................................................................. 44
4.4 WARM UP THE ENGINE AND THEHYDRAULIC SYSTEM ...................................................... 45
4.5 STOPPING THE ENGINE ................................................................................................................ 45
4.6 MACHINE MOVEMENT ................................................................................................................. 45
4.7 OPERATION OF WORKING EQUIPMENTS ................................................................................. 48
4.8 LOADING.......................................................................................................................................... 49
4.8.1 LOADING ON LEVEL FLOOR................................................................................................ 49
4.8.2 LOADING ON SLOPES............................................................................................................ 49
4.9 DIGGING........................................................................................................................................... 50
4.10 LEVELLING UP................................................................................................................................ 50
4.11 PARKING THE MACHINE.............................................................................................................. 51
4.12 ACCELERATION............................................................................................................................. 51
4.13 TRANSPORTING THE MACHINE ON OTHER VEHICLES......................................................... 52
4.13.1 LOADING THE MACHINE...................................................................................................... 52
4.13.2 SECURING THE MACHINE.................................................................................................... 52
4.13.3 UNLOADING THE MACHINE................................................................................................ 53
4.14 LIFTING THE MACHINE ................................................................................................................ 53
4.15 USE OF THE QUICK COUPLER ..................................................................................................... 53
4.15.1 HITCH THE BUCKET .............................................................................................................. 54
4.15.2 UNHITCH THE BUCKET......................................................................................................... 55
4.15.3 AJUST THE QUICK COUPLER MECHANISM ..................................................................... 55
4.16 USE OF AUXILIARY PEDAL.......................................................................................................... 55
4.17 HIGH FLOW SYSTEM ..................................................................................................................... 56
4.18 MAXIMUM IMMERSION IN AFLUID .......................................................................................... 56
4.19 MOVE THE MACHINE WITH TOWING HOOK............................................................................ 56
4.20 STARTING THE MACHINE WITH BOOSTER CABLES.............................................................. 57
4.21 LONG-TERM STORAGE................................................................................................................. 57
4.21.1 BEFORE LONG-TERM STORAGE......................................................................................... 57
4.21.2 DURING THE PERIOD OF INACTIVITY .............................................................................. 58
4.21.3 AFTER THE PERIOD OF INACTIVITY ................................................................................. 58
5MAINTENANCE...................................................................................................................................... 58
5.1 REQUIREMENT SERVICE.............................................................................................................. 58

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5.2 ADVICE FOR THE MAINTENANCE.............................................................................................. 59
5.3 GENERAL INFORMATION FOR CARRY OUT THE MAINTENANCE...................................... 60
5.3.1 OIL AND COOLANT AT CORRESPONDING ENVIRONMENTAL TEMPERATURE......60
5.3.2 CAPACITIES............................................................................................................................. 61
5.3.3 CODIFICATION OF THE MAIN CHANGED PART.............................................................. 62
5.3.4 TORQUE FOR SCREWS .......................................................................................................... 63
5.3.5 TOOL LIST................................................................................................................................ 63
5.3.6 LUBRICATION POINTS .......................................................................................................... 64
5.4 DESCRIPTION MACHINE FOR MAINTENANCE........................................................................ 64
5.4.1 ENGINE DESCRIPTION .......................................................................................................... 64
5.4.2 HYDRAULIC SYSTEM DESCRIPTION................................................................................. 65
5.4.3 ELECTRICAL SYSTEM........................................................................................................... 65
5.4.4 SAFETY BELT.......................................................................................................................... 65
5.5 MAINTENANCE PLAN ................................................................................................................... 65
5.5.1 BEFORE STARTING ................................................................................................................ 68
5.5.1.1 CHECKING ENGINE OIL LEVEL...............................................................................................................68
5.5.1.2 CHECKING ENGINE COOLANT LEVEL...................................................................................................68
5.5.1.3 CHECKING ENGINE FUEL LEVEL..................................................................................................................68
5.5.1.4 CHECKING THE HYDRAULIC OIL LEVEL..............................................................................................68
5.5.1.5 CHECKING THE ELECTRIC CABLES.......................................................................................................69
5.5.1.6 CHECKING THE TIRES...............................................................................................................................69
5.5.1.7 CHECKING THE SAFETY BELT ................................................................................................................69
5.5.1.8 CHECKING THE LEAKING OF OIL...........................................................................................................69
5.5.1.9 CHECKING THE QUICK COUPLER...........................................................................................................69
5.5.1.10 ECKING THE WATER AND SEDIMENTS SEPARATOR.............................................................................69
5.5.2 EVERY 50 HOURS OF OPERATION...................................................................................... 70
5.5.2.4 CHECKING THE COOLER PIPES...............................................................................................................70
5.5.2.5 CHECKING THE COOLANT LEVEL..........................................................................................................70
5.5.2.6 CHECKING THE TIRE PRESSURE.............................................................................................................70
5.5.2.7 GREASING THE PINS OF BOOM AND CYLINDERS ..............................................................................70
5.5.2.8 CHECKING THE WHEEL NUT DRIVING TORQUE.................................................................................70
5.5.3 EVERY 100 HOURS OF OPERATION.......................................................................................... 71
5.5.3.1 CLEANING THE TERMINALS OF THE BATTERY........................................................................................71
5.5.3.2 CLEANING THE OIL TANK’S BREATHER ....................................................................................................71
5.5.3.3 CHECKING THE CYLINDER RODS ................................................................................................................71
5.5.3.4 GREASING ALL OF PINS..................................................................................................................................71
5.5.4 VERY 250 HOURS OF OPERATION ............................................................................................ 71
5.5.4.1 CHECKING THE GEARING CHAIN TENSION...............................................................................................71
5.5.4.2 ADJUSTING THE CHAIN IF NECESSARY......................................................................................................71
5.5.4.3 CHECKING THE FAN BELT.............................................................................................................................72
5.5.4.4 CLEANING THE RADIATOR............................................................................................................................72
5.5.4.5 CHECKING THE OIL LEVEL IN THE GEAR CHAIN.....................................................................................72
5.5.4.6 CHANGING THE ENGINE OIL.........................................................................................................................72
5.5.4.7 CHANGING THE ENGINE OIL FILTER...........................................................................................................72
5.5.4.8 CHANGING THE FUEL FILTER.......................................................................................................................73
5.5.4.9 CHECKING THE NUT TORQUE OF THE HYDARULIC MOTOR AND THE HUB HOLDING TO THE
CHASSIS..........................................................................................................................................................................74
5.5.5 EVERY 500 HOURS OF OPERATION.......................................................................................... 74
5.5.5.1 CLAEN THE FUEL-WATER SEPARATOR......................................................................................................74
5.5.5.2 CHECK THE TIGHTENESS OF PUMP FIXING SCREWS..............................................................................75
5.5.5.3 CHECKING THE FLUID LEVEL OF THE BATTERY.....................................................................................75
5.5.5.4 CHANGING THE HYDRAULIC OIL FILTER..................................................................................................75
5.5.6 EVERY 1000 HOURS OF OPERATION.................................................................................. 75
5.5.6.1 CHANGING THE OIL IN THE GEAR CHAIN BOX...................................................................................75
5.5.6.2 CHANGING THE HYDARULIC OIL AND CLEAN THE SUCTION ........................................................76
5.5.6.3 CHANGING THE AIR FILTER ....................................................................................................................76
5.5.6.4 CHECKING THE PUMP’S PRESSURE AND THE VALVE.......................................................................77
5.5.6.5 CHANGING THE HYDRAULIC OIL TANK BREATHER.........................................................................77
5.5.6.6 CHECKING THE TIGHTNESS OF THE CYLINDER HEAD SCREW.......................................................77
5.5.6.7 CHECKING THE LOOSENESS OF THE VALVE.......................................................................................77
5.5.7 EVERY 2000 HOURS OF OPERATION.................................................................................. 77
5.5.7.1 CHANGING THE COOLANT.......................................................................................................................77
5.5.7.2 CHECKING THE STARTER AND ALTERNATOR....................................................................................77
5.5.8 WHEN REQUIRED ......................................................................................................................... 77
5.5.8.1 DRAINING THE FUEL TANK...........................................................................................................................77
5.5.9 TROUBLE SHOOTING................................................................................................................... 78
6OPTIONAL EQUIPMENT ....................................................................................................................... 82

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6.1 SECURITY MEASURES.................................................................................................................. 82
6.2 SECURITY MEASURES FOR INSTALLATION............................................................................ 83
6.3 PERFORMANCE OF THE OPTIONAL EQUIPMENT ................................................................... 83
6.4 REPLACEMENT OF OPTIONAL EQUIPMENT ............................................................................ 83
6.5 CONNECTION OF HYDRAULIC CIRCUIT................................................................................... 84
6.5.1 CONNECTION OF STANDARD HYDRAULIC CIRCUIT.................................................... 84
6.5.2 CONNECTION OF HIGH FLOW HYDRAULIC CIRCUIT (FOR OPTION WITH HIGH
FLOW SYSTEM)...................................................................................................................................... 84
7OTHER DATA.......................................................................................................................................... 85
7.1 ELECTRIC DIAGRAM..................................................................................................................... 85
7.2 ELECTRIC ELEMENTS CHART..................................................................................................... 86
7.3 HYDRAULIC DIAGRAM ................................................................................................................ 87
8 INFORMATION OF MANUFACTURER.................................................................................................. 88

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1INTRODUCTION
1.1 MODELS AVAILABLE
This manual is special for the SWL series skid-steer loader. A series of skid-steer loaders
“SWL” are developed by SUNWARD INTELLIGENT EQUIPMENT CO., LTD, SUNWARD
INTELLIGENT EQUIPMENT CO., LTD own all intelligence property related to this machine.
1.2 ABOUT THIS MANUAL
This manual contents all the information about the SWL machine. The safety regulations,
description, use and maintenance instructions are included in this manual. SUNWARD
INTELLIGENT EQUIPMENT CO., LTD supply this manual together with the spare parts book.
He provides the user all information related to the SWL skid-steer loader and all safety
regulations.
For more information, please contact your SWL dealer. The dealer knows how to get the best
performance of the machine and how to use the machine correctly in any case.
1.3 TREATMENT OF THIS MANUAL
This operation and maintenance manual must be handled
with great care and always kept in the machine, so
that the operator can consult it at any moment. There
is a compartment special for operation manual and s
pare parts inside cabin. It locates on the behind of
the seat. See the right picture. The operation manual
must be always kept in this case.
In case of damage or lose this manual, request to
SUNWARD INTELLIGENT EQUIPMENT CO., LTD
or the SWL dealers for a new one.
1.4 UNITS
In this manual we have taken the international unit system. We are using millimeter for distance,
liter for volume, degree for angle, etc.
ITEM UNIT SYMBOL
Distance Millimeter mm
Volume Liter L
Angle Degree °
Temperature Celsius degree °C
Sound Decibel dB
1.5 DEFINITION OF “LEFT” SIDE AND “RIGHT” SIDE
In this manual, “left” and “right” imply your left hand side and right hand side when you are
seated properly in the machine. It is also showed in the picture below.

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RIGHT
LEFT
1.6 PRECONDITION TO USE THE MACHINE
To use this skid-steer loader properly and safely, operator must know well about this machine
and have basic experience on using this kind of machine. If you are a new operator of skid-steer
loader, please do not work with this machine before you get a special training on it.
The operator must take special attention on the security recommendation in order to preserve his
security and the security of persons around him.
Do not work with the machine until you are sure that you can control it properly. Do not begin a
work until you are sure there is no danger for you and for people around you.
If you have any doubt regarding the safety regulations, please contact your SWL dealer.
1.7 Signals
To help you to use machine safely, we have described many safety precautions in this manual.
Also many precaution labels are put on the machine. Many different signal words are used in the
manual and on the labels.
The following signal words are used to inform you that there is a potential hazardous situation
that may lead to personal injury and damage. In this manual and on the precaution labels on the
machine, the following signal words are used to express the level of the potential hazardous.
If not avoided, it has great possibility to lead to serious
injuries or death to the operator (or other persons). It is used
to express the most extreme dangerous situation.

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If not avoided, this situation could cause serious injuries
even death.
If not avoided, this situation may cause minor or moderate
injury to operator (or other persons) or damage to the
machine.
There are other signal words showed under to indicate precautions that are useful for operator.
It is used for precautions that must be taken to avoid actions
what could shorten the life of the machine.
It is used for information that is extremely useful to know.
The safety message may not include all the possible safety precautions. It is impossible to
describe all the potential hazard may appear during the operation or maintenance. For any
question regarding the safety regulation please contact your dealer.

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2SECURITY
This section describes the possible hazards that may appear during the operation and
maintenance of the machine. Authorized additional equipments have their manual given
together with the equipments.
2.1 MEANING OF THE SAFETY SIGNS
Safety precaution labels are fixed to the machine to warn about possible hazards that may cause
personal injuries or even death. They are placed where the possible danger is. Before using the
machine make sure you understand all the security labels. Keep all the labels clean and readable.
Change all the damaged labels.
2.1.1GENERAL SIGNS
The following table shows the different labels fixed on the machine and the respective meanings.
GENERAL LABELS
Moving crawlers, when Entanglements in can cause
serious injury High temperature
See manual book
Note
Float
Tail warning

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Oil level Diesel Oil
Oil filter Safety pin for boom
Lifting points
Drag position
Operation direction Operation direction