SUNWARD SWE150F Manual
Operation & Maintenance
Manual
SWE150F/SWE210F
HYDRAULIC EXCAVATOR
Sunward Intelligent Equipment Co.,Ltd
2015-07
I
Foreword
It is particularly important that the operator should read these instructions carefully in order
to operate and maintain the excavator safely and correctly. Otherwise accidents or damage may
occur.
The manual supplies safety rules and labels which have been fixed on the machine so as to
provide the instructions of potential danger and the ways to avoid it.
SUNWARD cannot predict any kind of potential danger may occur in the process of
operation and maintenance. Therefore, the related instructions in this manual and on the machine
only concern the basic safety rules. It is the operator’s duty to take necessary measures to protect
safety if there is no corresponding method recommended in this manual.
The forbidden usages or operations that mentioned in this manual can not be engaged in any circumstances.
The excavator is designed according to the metric system, all the data presented are metric and only metric
parts and apparatus can be used.
The manual should be regarded as the permanent part of excavator and kept at the easy
reading place for consultation at any time. If it is damaged or lost, please contact SUNWARD or
agents for ordering. The manual should be attached when the excavator is transferred or sold.
Use only trained, qualified and experienced operator to operate , check and maintain the
machine.
The equipment covered by this manual meets the applicable technical specifications
effective as of its date of issue. The manufacturer SUNWARD reserves the rights to make any
modification from time to time and without prior notice to any excavator components.
Please contact SUNWARD or agents for the updated information or the information
problem concerned in this manual.
Sunward Intelligent Equipment Co.,Ltd
II
Table of contents
1 Safety rules..................................................................................................................................................1
1.1 Safety labels .....................................................................................................................................2
1.1.1 Location of safety labels........................................................................................................2
1.1.2 Safety labels instruction ........................................................................................................3
1.2 General safety information .............................................................................................................16
1.2.1 Observe safety instruction ...................................................................................................16
1.2.2 Understand safety label .......................................................................................................17
1.2.3 Emergency protection..........................................................................................................18
1.2.4 Protective articles ................................................................................................................18
1.2.5 Safety equipment.................................................................................................................18
1.2.6 Keep machine clean.............................................................................................................19
1.2.7 Pre-start inspection ..............................................................................................................19
1.2.8 Instruction of entry into cab.................................................................................................19
1.2.9 Mounting and dismounting..................................................................................................20
1.2.10 Adjust operator’s seat ........................................................................................................20
1.2.11 Fasten seatbelt....................................................................................................................20
1.2.12 Secure perfect visibility.....................................................................................................21
1.2.13 Leave operator seat............................................................................................................21
1.2.14 Emergency exit way ..........................................................................................................21
1.2.15 Prohibit passenger .............................................................................................................21
1.2.16 Worksite safety ..................................................................................................................22
1.2.17 Operation around loosened area ........................................................................................22
1.2.18 Signals and gestures from flagman....................................................................................23
1.2.19 Distance to high voltage cables .........................................................................................23
1.2.20 Prevent scald......................................................................................................................24
1.2.21 Stay away from power driven parts ...................................................................................24
1.2.22 Prevent fire and explosion .................................................................................................24
1.2.23 Fire prevention...................................................................................................................25
1.2.24 Prevent fly-out or falling object.........................................................................................25
1.2.25 Prevent fly-out parts ..........................................................................................................25
1.2.26 Avoid inhaling asbestos dust..............................................................................................26
1.2.27 Cautious not to inhale exhaust gas ....................................................................................26
1.2.28 Safety rules for high pressurized fluid...............................................................................26
1.2.29 Safe disposal of fluid .........................................................................................................27
1.2.30 Chemical disposal..............................................................................................................27
1.2.31Waste material disposal ......................................................................................................27
1.2.32 Unauthorized modification to machine .............................................................................27
1.3 Safe operation instruction...............................................................................................................28
1.3.1 Checks before starting engine..............................................................................................28
1.3.2 Proper engine start...............................................................................................................29
1.3.3 Start engine in cold weather.................................................................................................29
1.3.4 Safe operation......................................................................................................................30
III
1.3.5 Operation on slopes .............................................................................................................30
1.3.6 Operation on snow...............................................................................................................31
1.3.7 Avoid tipping over ...............................................................................................................31
1.3.8 Prevent accidents during slewing and reversing..................................................................32
1.3.9 Avoid runaway accident.......................................................................................................33
1.3.10 Machine movement ...........................................................................................................33
1.3.11 Safety rules during traveling..............................................................................................34
1.3.12 Travel on slope ..................................................................................................................35
1.3.13 Safety rules during towing.................................................................................................36
1.3.14 Machine transportation......................................................................................................36
1.3.15 Parking machine ................................................................................................................37
1.4 Safety maintenance information.....................................................................................................38
1.4.1 Use warning signs................................................................................................................38
1.4.2 Parking the machine prior to service ...................................................................................38
1.4.3 Safety maintenance rules.....................................................................................................39
1.4.4 Use hammer.........................................................................................................................40
1.4.5 Welding and grinding precautions .......................................................................................40
1.4.6 Avoid heating pipeline containing flammable gas...............................................................40
1.4.7 Avoid heating around hydraulic pressure pipeline...............................................................41
1.4.8 Remove paint prior to welding or heating operation ...........................................................41
1.4.9 Accessories ..........................................................................................................................41
1.4.10 Maintenance precaution of track tension mechanism........................................................42
1.4.11 Safety rules for high-pressure oil.......................................................................................42
1.4.12 Safety handling high-pressure hoses .................................................................................43
1.4.13 Accumulator ......................................................................................................................43
1.4.14 Prevent accumulator explosion..........................................................................................44
1.4.15 Waste disposal ...................................................................................................................44
2 Transportation and storage ........................................................................................................................45
2.1 Transportation.................................................................................................................................46
2.1.1 General transportation instruction .......................................................................................46
2.1.2 Transportation specification ................................................................................................46
2.1.3 Loading or unloading with trailer........................................................................................47
2.1.4 Loading................................................................................................................................48
2.1.5 Secure the machine..............................................................................................................49
2.1.6 Unloading ............................................................................................................................50
2.1.7 Lifting procedure for the machine .......................................................................................51
2.2 Storage............................................................................................................................................53
2.2.1 Before storage......................................................................................................................53
2.2.2 During storage .....................................................................................................................54
2.2.3 After storage ........................................................................................................................54
3 Operation...................................................................................................................................................55
3.1 Overall machine view.....................................................................................................................56
3.2 Control and gauges.........................................................................................................................57
3.2.1 View illustration ..................................................................................................................57
3.2.2 Pilot safety lock lever ..........................................................................................................58
3.2.3 Travel control lever..............................................................................................................59
IV
3.2.4 Air condition control panel ..................................................................................................60
3.2.5 Multifunction monitor system ..........................................................................................61
3.2.6 Right pilot control joystick ..................................................................................................81
3.2.7 Horn switch .........................................................................................................................81
3.2.8 Left pilot control joystick ....................................................................................................82
3.2.9 Automatic slow-down switch ..............................................................................................82
3.2.10 Starting switch ...................................................................................................................83
3.2.11 Fuel control knob...............................................................................................................83
3.2.12 Working lamp switch.........................................................................................................84
3.2.13 Wiper switch......................................................................................................................84
3.2.14 Washer switch....................................................................................................................84
3.2.15 DPD Regeneration Switch.................................................................................................85
3.2.16 DPD Regeneration Lamp...................................................................................................85
3.2.17 Engine Stop Switch ...........................................................................................................85
3.2.18 Memory Clear Switch........................................................................................................86
3.3 Other part operation instruction......................................................................................................87
3.3.1 Cab windows .......................................................................................................................87
3.3.2 Cover, hood with lock..........................................................................................................90
3.3.3 Lighter .................................................................................................................................92
3.3.4 Radio ...................................................................................................................................92
3.3.5 Seat………………………………………………………………………………………..95
3.3.6 Fuse .....................................................................................................................................96
3.3.7 Air condition instruction......................................................................................................97
3.3.8 Accumulator ......................................................................................................................104
3.4 Operation and control of the machine ..........................................................................................105
3.4.1 Operator’s position. ...........................................................................................................105
3.4.2 Setting and adjustment. .....................................................................................................105
3.4.3 Work mode selection .........................................................................................................106
3.4.4 Inspection before starting the engine Walk-around inspection ..........................................107
3.4.5 Starting engine...................................................................................................................108
3.4.6 New machine running-in ...................................................................................................110
3.4.7 Warm up machine operation in cold weather .................................................................... 111
3.4.8 Operation safety rules........................................................................................................112
3.4.9 Machine traveling..............................................................................................................114
3.4.10 Steering the machine .......................................................................................................115
3.4.11 Upper-carriage swing.......................................................................................................117
3.4.12 Operate work equipments................................................................................................117
3.4.13 Work ................................................................................................................................118
3.4.14 Boom emergency stop .....................................................................................................123
3.4.15 Parking machine ..............................................................................................................123
3.4.16 Machine stop and emergency stop...................................................................................124
3.4.17 Handing the Engine with Diesel Particulate Defuser （DPD) .......................................125
3.4.18 Prohibited operations.......................................................................................................127
4 Maintenance and service .........................................................................................................................129
4.1 Maintenance information..............................................................................................................130
4.1.1 Instruction of maintenance and inspection ........................................................................130
V
4.1.2 Daily inspection prior to start-up.......................................................................................130
4.1.3 Check hour meter frequently .............................................................................................131
4.1.4 Preparation work prior to maintenance..............................................................................131
4.1.5 Handle fuel and lubricant properly. ...................................................................................131
4.1.6 Check discharged grease and used filter............................................................................131
4.1.7 Checks after inspection and maintenance..........................................................................132
4.1.8 Electrical system maintenance...........................................................................................132
4.1.9 Hydraulic system maintenance..........................................................................................133
4.2 Oil, coolant and filter....................................................................................................................133
4.2.1 Lubricant and hydraulic oil................................................................................................133
4.2.2 Fuel....................................................................................................................................134
4.2.3 Coolant in cooling system .................................................................................................134
4.2.4 Grease................................................................................................................................134
4.2.5 Oil and fuel storage ...........................................................................................................134
4.2.6 Filter ..................................................................................................................................134
4.2.7 Fuel and coolant specifications..........................................................................................135
4.3 Tightening torque specification ....................................................................................................136
4.3.1 Tightening torque table for bolt, nut..................................................................................136
4.3.2 Tightening torque table for hose........................................................................................137
4.4 Maintenance schedule ..................................................................................................................138
4.4.1 Add lubricating grease.......................................................................................................138
4.4.2 Engine oil ..........................................................................................................................139
4.4.3 Gear oil ..............................................................................................................................140
4.4.4 Hydraulic system...............................................................................................................141
4.4.5 Fuel system........................................................................................................................142
4.4.6 Intake/Exhaust System ......................................................................................................142
4.4.7 Cooling system ..................................................................................................................143
4.4.8 Other..................................................................................................................................143
4.4.9 Hose...................................................................................................................................144
4.4.10 Wearing parts table ..........................................................................................................145
4.4.11 Maintenance in special situation......................................................................................146
4.5 Machine maintenance interval......................................................................................................147
4.5.1 Daily maintenance (every 8 hours)....................................................................................147
4.5.2 Maintenance in running-in period. ....................................................................................152
4.5.3 If maintenance is needed ...................................................................................................159
4.5.4 Every 50 hours...................................................................................................................167
4.5.5 Every 100 hours.................................................................................................................167
4.5.6 Every 250 hours.................................................................................................................167
4.5.7 Every 500 hours service ....................................................................................................171
4.5.8 Every 1000 hours service. .................................................................................................173
4.5.9 Every 2000 hours service ..................................................................................................177
4.6 General trouble shooting ..............................................................................................................178
5 Technical specification ............................................................................................................................186
5.1 SWE150F Technical specification................................................................................................187
5.1.1 Machine specification........................................................................................................187
5.1.2 Configuration specification ...............................................................................................188
VI
5.1.3 Work specification .............................................................................................................189
5.1.4 Circuit diagram..................................................................................................................190
5.1.5 Electric elements table.......................................................................................................191
5.1.6 Hydraulic diagram.............................................................................................................192
5.1.7 Hydraulic elements table ...................................................................................................193
5.2 SWE210F Technical specification................................................................................................194
5.2.1 Machine specification........................................................................................................194
5.2.2 Configuration specification ...............................................................................................195
5.2.3 Work specification .............................................................................................................196
5.2.4 SWE210F Circuit diagram ................................................................................................197
5.2.5 SWE210F Electric elements table ..................................................................................198
5.2.6 Hydraulic diagram.............................................................................................................199
5.2.7 Hydraulic elements table ...................................................................................................200
6. Accessories and option parts ..................................................................................................................201
6.1 Safety items ...............................................................................................................................201
6.2 Attentions of mounting accessories ..............................................................................................201
6.3 Hydraulic quartering hammer(option)..........................................................................................202
6.3.1 Main use of hydraulic quartering hammer：.....................................................................202
6.3.2 Hydraulic hammer assembly .............................................................................................202
6.3.3 Control hydraulic quartering hammer ...............................................................................203
6.3.4 Operation safety of hydraulic quartering hammer.............................................................205
6.4 Option list .....................................................................................................................................208
7 Manufacture information.........................................................................................................................209
1
1 Safety rules
Warning
Please thoroughly read and completely understand all
precautions described in this manual or safety labels. Follow
all instructions when operating or servicing this machine.
2
§1 SAFETY RULES
1.1 Safety labels
1.1.1 Location of safety labels
Fully understand the correct position and contents of safety labels in this machine.
To ensure that the content of labels can be read properly, be sure that they are in right place and
always keep them clean. When cleaning them, do not use solvents or gasoline. It may cause
labels to peel off.
There are also other labels in addition to warning labels. Handle these labels in the same way.
In case the labels are damaged, lost or not legible, replace them with new ones. For details of
the part number, refer to parts manual or actual label, and place an order with SUNWARD or
our authorized distributors.
Actual position of safety labels in the machine
3
1.1.2 Safety labels instruction
（1）Precaution for operation
Please carefully read all safety precautions
written in labels and all information
concerning safety, prior to operate machine.
Maintenance frequently and replace safety
label if required. In case that safety labels or
manual are damaged or lost, you can place an
order with our distributors. The procedure of
ordering them is identical with that of the other
parts and components. You must specify model
of the machine when ordering.
Use only trained and qualified personnel to
operate this machine. Follow all safety
precautions and instructions in this manual to
keep your machine in good condition.
Do not alter or modify machine rashly, this
may impair function and effect service life or
jeopardize personal safety.
Caution: all safety information described in
this manual covers only basic safety
information of this machine. It’s not possible to
predict every circumstance which might
involves potential hazards. So it’s necessary to
ask for instruction from your superior before
attempting any operation or maintenance
procedure.
4
（2）Precaution for operating engine
Diesel engine inspection
Stop machine on level ground, inspect engine
oil level (stop engine for longer than 15
minutes to allow engine oil to go back to the
bottom), inspect dipstick to make sure oil level
must be between the lines of “MIN” and
“MAX”. For engine maintenance procedures,
please refer to the “diesel engine maintenance
manual” enclosed with the other literature of
the machine.
Pre-start inspection
Keep control lever of pilot valve in LOCK
position, pilot handle and travel pull link are in
normal position (neutral position), operator sit
over seat.
While switching the key to ON position,
except engine hour meter and LCD module, all
indicators of test system must light up. Buzzer
must sound as well. Self-test is finished in 2
seconds to indicate test system is or is not
properly functioning.
Start the engine
Keep control lever of pilot valve at LOCK
position.
Switch key to ON position.
Sound horn to alert the persons around.
Turn the key to the right; hold it in START
position until engine runs. Then release the key,
switch will automatically. Return to ON
position.
Caution
Do not operate motor for longer than
5 seconds ever time to avoid damage
to machine. In case of failure to
start engine, switch the key back to
OFF position, wait 2 minutes before
a new attempt. Incorrect start may
damage to starter.
5
（3）Diesel label
Caution
Refilling fuel with extra care. Stop
engine before refilling fuel. Do not
smoke while refilling to fuel tank or
operating around fuel system.
Select proper fuel according to
different ambient temperature.
Refer to “stop engine” section for properly
parking machine and stopping engine.
Inspect fuel gauge on monitor, top up is
required.
Prevent dirt, dust, water and other foreign
matter from entry into oil tank and fuel system.
While refilling at the end of daily work-shift,
do not spill, drip any fuel to machine or ground
to avoid fuel clotting.
After refilling fuel, fasten cap securely.
6
（4）Machine posture symbol
Caution
Do not start engine when hydraulic
oil tank runs out of oil.
Inspect hydraulic oil level……daily
Park machine on level ground.
Completely retract arm cylinder and extend
bucket cylinder to full length.
Lower bucket down to the ground.
Run engine at low speed for 5 minutes.
Shut down engine, remove the key.
Place pilot control lever to LOCK (up)
position.
Open right side door to check oil level gauge.
Located on hydraulic oil tank, oil level must be
within level marks. Pump oil if level is higher
than MAX mark, refill if level is below MIN
mark.
add oil：
Remove upper breather screw cap by rotating
anticlockwise.
Refill oil through strainer. Recheck oil level
gauge.
Fasten cap securely.
7
（5）Service and lubrication symbol.
Proper procedure of maintenance and
inspection
Learn about how to properly service machine.
Perform proper maintenance and inspection
procedure in accordance with this manual. Inspect
machine before starting machine.
Check monitor.
Check individual liquate level.
Check hose and piping for leakage, twist, wear
out or damage.
Check surrounding the machine for any signs
of noise, heat etc.
Check parts for looseness and lost.
Caution
If any problems are detected, repair
prior to operation, or contact our
authorized distributor.
Use recommended fuel, hydraulic oil and
lubricant.
Use only genuine SUNWARD components.
The warranty is not applicable for any
damages arising from failure to use
SUNWARD recommended fuel, lubricant,
hydraulic oil and genuine SUNWARD
components.
Do not adjust speed limiting governor of
engine or safety valve of hydraulic system.
Do not allow water or vapor to reach electrical
equipment.
Do not disassemble components such as engine
pump controller, sensor etc.
8
（6）Wiper label
Properly use wiper.
（7）Filter core safety label
Replace pilot oil filter every 400 hours
Stop machine on a firm and level ground.
Lower bucket to the ground.
Run engine at low-speed for 5 minutes.
Shut down engine, remove the key.
Relieve internal pressure which builds up in
hydraulic system by means of left/right pilot
joystick.
Set pilot control lever in LOCK (UP) position.
Use wrench for filter to remove filter housing
off the filter head cover by rotating
counterclockwise.
Remove filter core and used 0-ring.
Clean the area in contact by head cover and
o-ring.
Apply a new layer of fresh hydraulic oil, and
place it in position.
Lubricate new filter core with a thin layer of
clean hydraulic oil on the ring section. Push
filter core upward while moving it forward and
backward alternately to install it.
Clean filter housing.
Rotate clockwise to tighten filter shell to head
cover. Tighten at torque: 19.5—29.5Nm (2-3
kgfm).
9
（8）Engine hood label
Warning
Shut down engine before opening
engine hood.
Be cautious of scalding after opening
engine hood.
（9）Working device label
Warning
Stay clear of working device.
（10）Swing label
Warning
Keep clear of swing area.
（11）Rump label
Warning
Stay clear of machine while it is
running.
（12）Lifting direction label
10
（13）Traction hook
（14）Anti- scald label
After running operation, engine oil, gear oil
and hydraulic oil is getting hot, so do engine,
hoses, pipelines or other components. Be
cautious of scalding.
Attempt inspection and maintenance procedure,
after machine components and oil cool down.
There is pressure in existence in hydraulic oil
tank. Relieve pressure before opening cap to
avoid oil spurt.
There is pressure which builds up in hydraulic
piping. Relieve pressure prior to repair or
replacing.
（15）Prevent hand being caught in fan blade.
Fan would run at high speed while engine is
active. Pay much attention to prevent hand,
foot, hair and clothing being caught in fan
blade, when attempting any inspection and
maintenance procedures on machine.
11
（16）Operation pictogram label
This machine is equipped with two pilot
control joystick and two travel control lever
which control working device motion, swing
action of upper turret, machine travel
accordingly.
The right pilot joystick controls motions as
below：
a、boom up-movement
b、boom down-movement
c、backhoe loading , or grab bucket rotate
clockwise
d、backhoe dumping, or grab bucket rotate
counter clockwise.
Left pilot joystick controls motion as below：
e、rotate upper carriage to
left(counterclockwise)
f、rotate upper carriage to right(clockwise)
g、extend arm
h、retract arm
Operation together with two pilot joysticks can
also execute compound motion. In addition,
horn switch button is fixed on the joystick.
Two travel control lever control forward
motion, reverse motion and steering of the
machine.
（17）Direction symbol
This label indicates travel direction of machine
when “travel control lever is pushed forward”.
Warning
In case that driving wheel is located
underneath cab, machine will tram in reverse
when pushing “ travel control lever ”
forward.(On this occasion, symbol indicates
backward).
12
（18）No unauthorized access label
Warning
Stay clear of operation area of
working device.
13
（19）Pilot safety lock label
（20）Fuel label
Warning
Handle fuel with extra care due to its
high flammable property. In case that
fuel is ignited, this can cause
explosion or fire, and even death or
injury to person.
Always refilling fuel at outdoor. Be sure to top
engine before refilling fuel.
Do not refill fuel while smoking or near fire or
sparks.
All fuel and most of lubricants are flammable.
Flammable liquid should be stored at proper
place far from fire.
Do not burn out or stab at pressurized
container.
Do not store rag containing oil. This can cause
self-ignition and can be lighted up.
Fasten cap of filling opening.
This manual suits for next models
1
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