SUNWARD SWTH634 Manual

Operation & Maintenance Manual
TELESCOPIC HANDLER
`
SUNWARD INTELLIGENT EQUIPMENT CO., LTD.

Preface
Copyrightand Amendment
Text and illustrations herewith enclosed may not be or duplicated, not even in part and by any
means. Even the title owner of the telescopic handlers just has the right of consulting this manual, this
manual may not be supplied to any other third party for looking up, or anybody will be liable the
above behavior.
Because of the possible time lag between the introduction of technical modifications (an
on-going process the aim of which is to offer products which are being continually improved) and the
latest up date of the manual, we must point out, for the sake of correctness, that the data contained in
this edition is liable to change at any time and are therefore not binding.
Introduction
Our telescopic lift trucks have been designed to ensure convenient manoeuvres and easy
maintenance.
Before operating the truck for the first time, the driver should read and become fully familiar
with the various chapters in this manual.
These instructions have been prepared to provide all the information required for proper servicing
and truck operation. By complying with these instructions, the truck driver will be able to get the best
performances from his vehicle.
The terms “right” and “left”, “front” and “rear” used in this manual refer to positions viewed by
the driver seated normally in the driving seat.
SUNWARD

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TABLE OF CONTENTS
PREFACE ......................................................................................................................................0
TABLE OF CONTENTS ....................................................................................................................1
1. SAFETY INSTRUCTIONS .........................................................................................................3
1.1 ORIGINAL REPLACEMENT PARTS AND ATTACHMENTS .............................................................. 3
1.2 DRIVER’S OPERATING INSTRUCTION................................................................................... 3
1.3 ENVIRONMENT.......................................................................................................................... 5
1.4 AUTHORIZATION TO OPERATE.................................................................................................. 5
1.5 OPERATING INSTRUCTIONS ..................................................................................................... 5
1.6 STOPPING THE TELESCOPIC HANDLER.................................................................................... 6
2. DESCRIPTION........................................................................................................................7
2.1 INSTRUMENT PANEL ................................................................................................................. 8
2.2 ACCELERATOR PEDAL（PIC. B）.......................................................................................... 11
2.3 FOOT BRAKE（PIC. A）........................................................................................................ 11
2.4 STEERING WHEEL ................................................................................................................... 11
2.5 KEY SWITCH........................................................................................................................... 11
2.6 EMERGENCY STOP SWITCH...................................................................................................... 11
2.7 ROCKER SWITCH CONSLE........................................................................................................ 12
2.8 BATTERY MAIN SWITCH ......................................................................................................... 12
2.9 COMBINATION CONTROL SWITCH............................................................................................ 13
2.10 ELECTRO-HYDRAULIC PROPORTIONAL SERVOCONTROLS........................................................ 14
2.11 SEAT....................................................................................................................................... 15
2.12 SAFETY BELT......................................................................................................................... 15
2.13 REARVIEW MIRROR ................................................................................................................. 16
3. MACHINE OPERATION.........................................................................................................17
3.1 AUTHORIZED OPERATION ....................................................................................................... 17
3.2 BEFORE STARTING THE LIFT TRUCK. .................................................................................. 17
3.3 START THE ENGINE ............................................................................................................... 18
3.4 ALTERNATOR........................................................................................................................... 18
3.5 DRIVE..................................................................................................................................... 19
3.6 STEER..................................................................................................................................... 19
3.7 STOPPING THE LIFT TRUCK.................................................................................................. 19
3.8 STEERING MODE ..................................................................................................................... 19
3.9 MOUNT THE ACCESSORY WITH MANUAL LOCK......................................................................... 21
3.10 LOAD HANDLING ..................................................................................................................... 23
4. TRANSPORT AND STORE .....................................................................................................26
4.1 SLING THE LIFT TRUCK........................................................................................................ 26
4.2 TRANSPORT THE LIFT TRUCK ON APLATFORM ..................................................................... 26
4.3 STORAGE................................................................................................................................. 27
4.3.1 Long-term storage..................................................................................................... 27
4.3.2 Before storage........................................................................................................... 27
4.3.3 During storage........................................................................................................... 27
4.3.4 After storage............................................................................................................. 27

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5. MAINTENANCE ................................................................................................................... 28
5.1 FILTERING ELEMENTS AND BELTS........................................................................................ 28
5.2 LUBRICANT............................................................................................................................. 28
5.3 SERVICING SCHEDULE CONTENT............................................................................................ 29
5.4 SERVICING SCHEDULE DESCRIPTION.................................................................................... 31
5.4.1 EVERY DAY OR EVERY 10 HOURS SERVICE................................................................. 31
5.4.2 EVERY 50 HOURS SERVICE........................................................................................... 32
5.4.3 EVERY 250 HOURS SERVICE......................................................................................... 34
5.4.4 EVERY 500 HOURS SERVICE......................................................................................... 37
5.4.5 EVERY 1000 HOURS SERVICE....................................................................................... 39
5.4.6 EVERY 2000 HOURS SERVICE....................................................................................... 40
5.4.7 EVERY 5000 HOURS SERVICE....................................................................................... 40
5.4.8 OCCASIONAL MAINTENANCE........................................................................................... 41
6. DESCRIPTION...................................................................................................................... 42
6.1 SPECIFICATION..................................................................................................................... 42
6.1.1 Engine........................................................................................................................... 42
6.1.2 Chassis......................................................................................................................... 42
6.1.3 Type............................................................................................................................... 42
6.1.4 Hydraulic circuit..................................................................................................... 42
6.2 SPECIFICATIONS................................................................................................................... 43
6.2.1 Performance................................................................................................................. 43
6.2.2 Parameter..................................................................................................................... 43
6.2.3 Gradeability............................................................................................................... 43
6.2.4 Noise level (in accordance with86/662/EEC)................................................... 43
6.3 DIMENSION AND LOAD CHARTS.............................................................................................. 44
6.3.1 DIMENSION..................................................................................................................... 44
6.3.2 LOAD CHARTS................................................................................................................. 45
7. ATTACHMENT TOOL ............................................................................................................ 46
7.1 ATTENTIONS........................................................................................................................... 46
7.2 ATTACHMENT TOOL ................................................................................................................. 47
7.2.1 Floating goods fork................................................................................................. 47
7.2.2 Light bucket............................................................................................................... 48
7.2.3 Clip with bucket....................................................................................................... 48
7.2.4 Clipping fork............................................................................................................. 49
7.2.5 Dozer blade................................................................................................................. 49
7.2.6 Hay fork....................................................................................................................... 50
7.2.7 Simple sling............................................................................................................... 50
8. APPENDIX ..........................................................................................................................51
8.1 ELECTRICAL SCHEMATIC DIAGRAM........................................................................................ 51
8.2 HYDRAULIC SYSTEM DIAGRAM................................................................................................ 52
9. MANUFACTURER DATA ....................................................................................................... 53

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1. SAFETY INSTRUCTIONS
1.1 ORIGINAL REPLACEMENT PARTS AND ATTACHMENTS
All maintenance on our lift trucks must be carried out using original parts.
By allowing non-original parts to be used, you run the risk:
Legally, of being liable in the event of an accident.
Technically, of causing breakdowns to occur or of reducing your lift truck's service life.
Using counterfeit parts or components not approved by the manufacturer may put an end to
contract warranty terms and lead the maker to withdraw the lift truck's certificate of compliance.
By using original parts during maintenance operations, you are legally covering yourself.
Any user who procures parts from another quarter does so at his own risk.
Any user who modifies his lift truck or has it modified by a service company, must consider that
a new item of equipment has been brought into the market and therefore takes liability for it.
Any user who copies original parts or has them copied is taking a risk from the legal viewpoint.
The certificate of compliance only binds the maker for parts chosen or produced under the
maker's control.
The practicalities of maintenance terms are set out by the maker. The maker is in no way liable in
the event of the user not complying with such terms.
The manufacturer brings to the user:
His know-how and skill.
Guaranteed quality work.
Original replacement parts.
Help with preventive maintenance.
Effective help with diagnosing faults.
Enhancements gained from feedback.
Training for operating staff.
Only the manufacturer knows the details of the lift truck design and therefore has the best
technological capability to carry out maintenance.
Original replacement parts are distributed exclusively by SUNWARD and its dealer network.
1.2 DRIVER’S OPERATING INSTRUCTION.
Caution Whenever you see this symbol it means :“Warning! Be careful! Your safety or the
safety of the lift truck is at risk.
Most accidents connected with the use, maintenance and repair of the lift truck are due to non
application of the basic safety instructions. By being aware of the risks to which you are exposed
and by taking the necessary preventive measures, you should be able to avoid accidents
occurring.
Any operation or manoeuvre not described in the instructions is prohibited, however, any person
who does use another method must first ensure that he is not putting himself, another person or
the lift truck in danger.
The manufacturer is not able to anticipate all possible risk situations. Therefore the safety
instructions and notices given in the user manual and on the lift truck are not exhaustive.
Any bending of the rules in safety notices or the user, maintenance or repair instructions for your
lift truck may result in serious, or even fatal, accidents.
We would remind users of the risks in driving at excessive speed with regard to traffic
conditions, particularly:
Risk of loss of control on a poor-quality track.
Increased stopping distance.
The user must remain in full control of his lift truck and should:
Adapt his speed to each situation in order to be maintain his own safety, that of others and of his

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equipment.
Always be aware of his stopping distance.
On the basis of experience, there are a number of possible situations in which operating the lift
truck is contra-indicated.
Such foreseeable abnormal uses, the main ones being listed below, are strictly forbidden.
The foreseeable abnormal behaviour resulting from ordinary neglect, but does not result from any
wish to put the machinery to any improper use.
The reflex reactions of a person in the event of a malfunction, incident, fault, etc. during
operation of the lift truck.
Behaviour resulting from application of the "principle of least action" when performing a task.
For certain machines, the foreseeable behaviour of such persons as:
apprentices, teenagers, handicapped persons and trainees tempted to drive a lift truck. Truck
drivers tempted to operate a truck to win a bet, in competition or for their own personal
experience.
The person in charge of the equipment must take these criteria into account when assessing
whether or not a person will make a suitable driver.
Get to know the telescopic fork lift truck on the terrain where it is to be used.
Transport the load with the boom lowered and fully retracted.
Position the forks at right-angles to the load to be lifted.
Drive the truck at a speed appropriate to conditions and the state of the ground.
Never go too fast or brake sharply with a load.
When picking up a load, check that the ground is as even as possible.
When the load is lifted, make sure that no one can interfere with the operation and always adopt
proper handling procedures only.
Never attempt to carry out operations which exceed the lift truck’s capabilities.
Never raise a load in excess of the lift truck’s capacity and never increase the size of the ballast.
Drive around obstacles.
Take care over electrical wires, trenches and recently-excavated or filled ground.
Never leave the engine running unattended.
Use the parking brake when depositing difficult loads or on sloping ground.
Never leave the truck parked with a raised load.
Never authorise anyone to approach or pass below a load.
Always think of safety and only transport well balanced loads.
Never lift a load using one fork only.
Drive with care and with reflexes alert.
When the lift truck is not in use, lower the forks to the ground and engage the parking brake.
Never leave the ignition key in the truck unattended.
Never leave the truck loaded on a gradient of over 15% even with the parking brake engaged.
When lifting a load, take care that nothing and no one interferes with the movement and adopt
proper handling procedures only.
Comply with the data provided in the load diagrams.
Never transport another person on the lift truck.
Whenever an implement is changed, to prevent damage to the hydraulic unions always proceed
as follows:
Stop the engine
Wait 1 minute for the circuit to depressurize Moreover check that the unions are clean.
Ensure that the coupling faces are clean.

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1.3 ENVIRONMENT.
1) A lift truck operating in an area without fire extinguishing equipment must be equipped with an
individual extinguisher. There are optional solutions, consult your agent or dealer.
2) Take into account climatic and atmospheric conditions of the site of utilisation.
3) For operation under average climatic conditions, i.e.: between -15 °C and + 35 °C, correct levels
of lubricants in all the circuits are checked in production. For operation under more severe
climatic conditions, before starting up, it is necessary to drain all the circuits, then ensure correct
levels of lubricants using lubricants properly suited to the relevant ambient temperatures. It is the
same for the cooling liquid.
Protection against frost (See chapter: LUBRICANTS AND FUEL in paragraph: 3-
MAINTENANCE ) .
Adaptation of lubricants (Ask your dealer for information).
Engine filtration.
Lighting (Working headlight).
4) Optional solutions exist, consult your dealer.
5) Use of a lift truck is prohibited in protected areas (e.g. refinery, explosive atmosphere). For use in
these areas, specific equipment is available as an option. Consult your dealer.
If necessary, consult your dealer.
1.4 AUTHORIZATION TO OPERATE
1) Only qualified personnel may use the lift truck. Its use is subject to authorization to operate
being given by the appropriate manager in the user establishment.
2) The user should always carry this authorization to operate with him while he is using the lift
truck.
3) The driver is not competent to authorize the driving of the lift truck by another person.
4) In addition, the vehicle should be used in accordance with good practice for the profession.
1.5 OPERATING INSTRUCTIONS
1) Wear clothes suited for driving the lift truck, avoid loose clothes.
2) Never operate the vehicle when hands or feet are wet or soiled with greasy substances.
3) For increased comfort, adjust the driver’s seat to your requirements and adopt the correct position
in the driver’s cab。
4) The operator must always be in his normal position in the driver’s cab. It is prohibited to have
arms or legs, or generally any part of the body, protruding from the driver’s cab of the lift truck.
5) Always remember to fasten your seat belt and adjust it to your requirements.
6) The control units must never in any event be used for any other than their intended purposes (e.g.
climbing onto or down from the lift truck, portmanteau, etc.).
7) If the control components are fitted with a forced operation (lever lock) device, it is forbidden to
leave the cab without first putting these controls in neutral.
8) Never allow a passenger to travel on the lift truck in the driver’s cab.
9) Before starting the lift truck , check the different levels:
Engine oil.
Hydraulic reservoir oil.
Transmission oil.
Cooling liquid.
10) Also check for possible leakage of oil, fuel or liquid from the lift truck.
11) Always drive the lift truck with the forks or attachment at approximately 300 mm from the
ground, i.e. in the transport position.
12) Familiarise yourself with the terrain where the lift truck is to be used.

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13) Ensure that the service brakes and the sound alarm are working properly.
14) Drive according to, and at an appropriate speed for, the conditions and state of the terrain.
15) Slow down before executing a turn.
16) In all circumstances make sure you are in control of your speed.
17) On damp, slippery or uneven terrain, drive slowly.
18) Brake gently, never abruptly.
19) Only use the lift truck’s forward/reverse lever from a stationary position and never do so
abruptly.
20) Do not drive with your foot on the brake pedal or with the parking brake on.
21) Always remember that hydrostatic type steering is extremely sensitive to movement of the
steering wheel, so turn it gently and not jerkly.
22) Never leave the I.C. engine on when the lift truck is unattended.
23) Look in the direction you are traveling and always keep clear visibility of the road. Use the left
and right rear view mirrors frequently and ensure that they are kept in good condition, are clean
and correctly adjusted.
24) Never use the truck in places poorly lighted.
25) When working at night, ensure that your lift truck is fitted with full beam lights.There are
optional solutions, consult your agent or dealer.
26) Drive round obstacles.
27) Check the closing and locking of the hood.
28) Whatever his experience as a truck driver is, the operator is advised to familiarize himself with
the position and operation of all the controls and instruments before operating the lift truck.
1.6 STOPPING THE TELESCOPIC HANDLER
1) Ensure you comply with this safety notice as stopping the engine without allowing it to cool
could cause damage to components damaging such parts.
2) Never leave the ignition key in the lift truck when the lift truck is unattended.
3) When the lift truck is stationary, place the forks or attachment on the ground, place the gear lever
in neutral, apply the parking brake and put the forward / reverse lever in neutral.
4) If the driver has to leave his cab, even or a moment, it is essential to place the gear lever in
neutral, apply the parking brake and put the forward/reverse lever in neutral.
5) Make sure that the lift truck is not stopped in any position that will interfere with the traffic flow
and at less than one metre from the track of a railway.
6) In the event of prolonged parking on a site, protect the lift truck from bad weather, particularly
from frost (Check the level of antifreeze), close the rear window, lock the cab door and ensure
that the hood is properly secured.
Stop instructions.
1) Park the lift truck on flat ground or on an incline lower than 15 %.
2) Place the forward/reverse lever in neutral.
3) Apply the parking brake.
4) Completely retract the boom.
5) Lower the forks or attachment to rest on the ground.
6) Stop the I.C. engine
7) Remove the ignition key.
8) Check the closing and locking of door, rear window and hood.
Before leaving your driver's cabin, ensure that you have carried out all operations for
stopping the lift truck, for your safety and the safety of others.

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2. DESCRIPTION
1.Telescopic boom 2.Dynamical system 3.Hydraulic cylinder
4.Cab 5.Travelling system 6.Quick-change system
7.Attachment tool 8.Covering parts 9.Fuel tank
10.Hydraulic fluid tank 11.Chassis

2.1 INSTRUMENT PANEL
Fuel gage
Indicates the quantity of diesel available in the tank
Engine cooling water-thermometer dash unit
If the temperature reaches 103°C, the warning light turns on,
immediately turn off the engine and troubleshoot the cause in the
cooling circuit.
Load indicator
The indicator shows the machine load torque, when then load torque
is bigger than the set value, the pointer will point to the red zone,
built-in torque limiter will automatically cut off the action,that may
cause the risk of tipping.
Engine speed indicator
Checking the rotation speed of engine.