SUNWARD SWE60UF Manual

Operation & Maintenance
Manual
SWE50B/SWE60B/SWE60UF/SWE70B/SWE80B
/SWE90UB/SWE70F/SWE80F/SWE90UF
Hydraulic Excavator
Sunward Intelligent Equipment Co.,Ltd.
Jan., 2019

I
FOREWORD
This manual will help users to operate and maintain the machine correctly.
It is particularly important that the machine operator should read these instructions carefully not
only prior to using the machine for the first time (in order to become acquainted with its
operation and special features), but also to take full advantage of its capabilities during use, or
for lubricating and servicing operations. Otherwise accidents or damage may occur.
The manual should be regarded as the permanent part of machine and kept in the cab for
consultation at any time. And the manual should be attached when the machine is transferred or
sold.
The machine is designed according to the metric system, all the data presented are metric and
only metric parts and apparatus can be used.
Position definition: RIGHT and LEFT always mean the left and right of an operator seated
correctly in the machine. The drive sprockets of undercarriage are located at the rear.
Keep your machine number on this manual correctly for future query. When you order parts,
dealers also need the number. If the manual is on the machine, please also keep these numbers
safety in machine aboard.
Sunward guarantees to keep machine in good repair in term of service. The service details are
showed in Maintenance Card supplied by distribution.
Maintenance Card guarantees can you get service or not in service period. In some conditions,
even if machine is out of service term, Sunward can also supply the in site free service in normal.
For best machine performance, all instructions given in this manual should be complied with
strictly. Possible warranty claims may be considered only provided that all operations are made
by qualified operator and scheduled inspections are made at the specified times by qualified
technician. Warranty claims will not be considered provided the machine is abused, overloaded,
or if there are changes to the original functions of machines.
Only the holder of the license issued by the government, qualified, experienced operators are
allowed to operate the machine. Similarly, only hold government issued license personnel can
inspection and maintenance of the machine.
Regarding SAFETY in particular, we recommend carefully reading the SAFETY RULES in this
manual and complying with all the safety rules.
All the information including charts and specifications in this manual is the latest that we can get.
We reserve the right to make without prior notice any modification or amendment to machine
component.
Sunward Intelligent Equipment Co., Ltd.

II
TABLE OF CONTENTS
1. SAFETY RULES............................................................................................................................................ 1
1.1 SAFETY MARK........................................................................................................................................ 1
1.2 SAFETY LABEL ....................................................................................................................................... 1
1.3GENERAL SAFETY INSTRUCTION....................................................................................................... 1
1.4 PREPEARE FOR EMERGENCY.............................................................................................................. 2
1.5 WEARING SAFETY PROTECTIVE ARTICLES .................................................................................... 2
1.6 CHECKING MACHINE BEFORE START-UP........................................................................................ 2
1.7 SEAT ADJUSTMENT............................................................................................................................... 3
1.8 ENTERING OR LEAVING MACHINE.................................................................................................... 3
1.9 STARTING ENGINE CORRECTLY........................................................................................................ 3
1.10 FORBID CARRYING PASSENGERS.................................................................................................... 3
1.11 KEEPING MACHINE AWAY FROM ELECTRICITY TRANSMISSION LINE.................................. 3
1.12 MOVING MACHINE SAFELY .............................................................................................................. 4
1.13 PREVENTING ACCIDENTS WHILE BACKING OR SWINGING...................................................... 4
1.14 DIGGING SAFELY................................................................................................................................. 5
1.15 AVOID MACHINE UNCONTROLLED................................................................................................. 5
1.16 PARKING MACHINE SAFELY............................................................................................................. 6
1.17 SAFE MAINTENANCE.......................................................................................................................... 6
1.18 SUPPORTING MACHINE SAFELY...................................................................................................... 7
1.19 CLEANING TRASH ON THE MACHINE ............................................................................................. 8
1.20 PREVENTING BATTERY FROM EXPLODING.................................................................................. 8
1.21 STORING PARTS SAFELY.................................................................................................................... 8
1.22 PREVENTING SPLASH OBJECTS........................................................................................................ 8
1.23 PREVENTING FLYING-OFF PARTS.................................................................................................... 8
1.24 AWAY FROM TRANSMISSION PARTS.............................................................................................. 9
1.25 PREVENTING ASBESTOS DUST INHALATION................................................................................ 9
1.26 BEWARE OF FOG OR GAS INHALATION.......................................................................................... 9
1.27 BEWARE OF SCALDING ...................................................................................................................... 9
1.28 BE CAREFUL TO PRESSURE LIQUIDS............................................................................................. 10
1.29 NO HEATING NEAR PRESSURE OIL PIPE....................................................................................... 10
1.30 NO HEATING INFLAMMABLE LIQUID PIPE .................................................................................. 10
1.31 ATTENTION ON WELDING &POLISHING...................................................................................... 11
1.32 REMOVING PAIN BEFORE WELDING OR HEATING.................................................................... 11
1.33 NOTES FOR WELDING ON MACHINE EQUIPPED WITH ELECTRONIC CONTROLLER AND
ENGINE......................................................................................................................................................... 11
1.34 DISPOSING LIQUID SAFELY............................................................................................................. 12
1.35 DISPOSING CHEMICAL SAFELY...................................................................................................... 12
1.36 PREVENTING FIRE.............................................................................................................................. 12
1.37 EMERGENCY EXIT ............................................................................................................................. 13
1.38 NOISE.................................................................................................................................................... 14
1.39 OTHER SAFETY MARKS.................................................................................................................... 14

III
2. MACHINE FAMILIARIZATION............................................................................................................. 16
2.1 CAB.......................................................................................................................................................... 17
2.2 MONITOR METER................................................................................................................................. 18
2.2.1 METER FUNCTIONS ....................................................................................................................... 19
2.2.2 DISPLAY RANGE AND ALARM STATEMENT................................................................................ 19
2.2.3 BUTTONS.......................................................................................................................................... 20
2.3 CONTROL PANEL ................................................................................................................................. 20
2.4 RADIO ..................................................................................................................................................... 22
2.4.1 Panel Functions................................................................................................................................. 22
2.4.2 Performance Index............................................................................................................................ 23
2.4.3 Operation Instructions ...................................................................................................................... 23
2.4.4 Radio Mute Button Switch................................................................................................................. 25
2.5 SEAT ADJUSTMENT............................................................................................................................. 25
2.6 AIR CONDITIONER............................................................................................................................... 26
2.7 PILOT CONTROL JOYSTICK ............................................................................................................... 26
2.8 THROTTLE CONTROL.......................................................................................................................... 27
2.9 CAB TOPLIGHT (OPTIONAL）........................................................................................................... 28
2.10 PLATFORM LIGHT.............................................................................................................................. 29
2.11 FRONT WINDOW................................................................................................................................. 29
2.12 WIND HOOD AND UPPER-COVER ................................................................................................... 29
2.13 LABELS................................................................................................................................................. 30
3. MACHINE OPERATION........................................................................................................................... 31
3.1 MACHINE WORKING ENVIRONMENT ............................................................................................. 31
3.2 RUNNING-IN OPERATION................................................................................................................... 31
3.3 ENGINE OPERATION............................................................................................................................ 32
3.4 TRAVELLING CONTROL..................................................................................................................... 36
3.5 EXCAVATION........................................................................................................................................ 39
3.6 EXCAVATOR PARKING....................................................................................................................... 41
3.7 LIFTING WORK ..................................................................................................................................... 45
3.8 HYDRAULIC HAMMER CRUSHER..................................................................................................... 46
3.9 BOOM SWING........................................................................................................................................ 50
3.10 AIR CONDITIONER OPERATION...................................................................................................... 51
3.11 ACCUMULATOR................................................................................................................................. 57
4.TRANSPORTATION AND STORAGE..................................................................................................... 58
4.1 GENERAL TRANSPORTATION RULES.............................................................................................. 58
4.2 TRANSPORT DIMENSION.................................................................................................................... 58
4.3 TRANSPORT ON HIGHWAY ............................................................................................................... 59
4.4 LOAD AND UNLOAD ........................................................................................................................... 60
4.5 STORAGE................................................................................................................................................ 62
5. MAINTENANCE......................................................................................................................................... 63
5.1 MAINTENANCE RULES ....................................................................................................................... 63
5.1.1 Correct Maintenance and Inspection Procedure .............................................................................. 63

IV
5.1.2 Checking Excavator Before Daily Starting....................................................................................... 64
5.1.3 Periodic Maintenance ....................................................................................................................... 64
5.1.4 Preparation for Maintenance............................................................................................................ 64
5.1.5 Using Fuel and Lubricant Correctly................................................................................................. 65
5.1.6 Checking Discharged Grease And Used Filter Core........................................................................ 65
5.1.7 Inspection After Maintenance ........................................................................................................... 65
5.1.8 Electrical System Maintenance ......................................................................................................... 65
5.1.9 Hydraulic System Maintenance......................................................................................................... 66
5.2 OIL, COOLANT AND FILTER............................................................................................................... 67
5.2.1 Lubricant and Hydraulic Oil............................................................................................................. 67
5.2.2 Fuel ................................................................................................................................................... 67
5.2.3 Coolant in Cooling System................................................................................................................ 68
5.2.4 Grease ............................................................................................................................................... 68
5.2.5 Oil and Fuel Storage......................................................................................................................... 68
5.2.6 Filter.................................................................................................................................................. 69
5.2.7 Fuel and Coolant Specification......................................................................................................... 70
5.3 TIGHTENING TORQUE SPECIFICATION .......................................................................................... 71
5.3.1 Tightening Torque Table for Bolts and Nuts..................................................................................... 71
5.3.2 Tightening Torque Table for Hoses................................................................................................... 72
5.4 ENGINE MAINTENANCE GUIDE........................................................................................................ 72
5.4.1 Adding Lubrication Grease............................................................................................................... 72
5.4.2 Engine Oil ......................................................................................................................................... 73
5.4.3 Gear Oil ............................................................................................................................................ 74
5.4.4 Hydraulic System............................................................................................................................... 75
5.4.5 Fuel System ....................................................................................................................................... 76
5.4.6 Air Filter............................................................................................................................................ 77
5.4.7 Cooling System.................................................................................................................................. 77
5.4.8 Air Conditioner Maintenance............................................................................................................ 78
5.4.9 DPF Regeneration............................................................................................................................. 79
5.4.10 Others.............................................................................................................................................. 82
5.4.11 Hose................................................................................................................................................. 83
5.4.12 Wearing Parts Table ....................................................................................................................... 84
5.4.13 Maintenance under Special Situation.............................................................................................. 85
5.4.14 Protective Measures for Long Time Storage................................................................................... 86
5.5 MACHINE MAINTENANCE SCHEDULE............................................................................................ 87
5.5.1 Daily Maintenance (Every 8 Hours) ................................................................................................. 87
5.5.2 Maintenance in Running-in Period (First 50 Hours)........................................................................ 90
5.5.3 If Maintenance is Needed.................................................................................................................. 94
5.5.4 Every 50 hours .................................................................................................................................. 98
5.5.5 Every 100 Hours................................................................................................................................ 99
5.5.6 Every 250 hours ................................................................................................................................ 99
5.5.7 Every 500 Hours Service................................................................................................................. 102
5.5.8 Every 1000 Hours Service............................................................................................................... 103
5.5.9 Every 2000 Hours Service............................................................................................................... 106

V
5.6 FAULT AND REPAIR................................................................................................................................. 106
5.6.1 Beyond Faults.................................................................................................................................. 106
5.6.2 Fault Examine and Repair .............................................................................................................. 107
6. TECHINIAL SPECIFICATION .............................................................................................................. 117
6.1 SWE50B TECHNICAL SPECIFICATION ........................................................................................... 117
6.1.1 Machine Specification..................................................................................................................... 117
6.1.2 Boundary Dimension....................................................................................................................... 118
6.1.3 Work Specification .......................................................................................................................... 119
6.1.4 Circuit Diagram.............................................................................................................................. 120
6.1.5 Electrical Elements Table ............................................................................................................... 121
6.1.6 Hydraulic Diagram ......................................................................................................................... 122
6.1.7 Hydraulic Elements Table............................................................................................................... 123
6.2 SWE60B TECHNICAL SPECIFICATION ........................................................................................... 124
6.2.1 Machine Specification..................................................................................................................... 124
6.2.2 Boundary Dimension....................................................................................................................... 125
6.2.3 Work Specification .......................................................................................................................... 126
6.2.4 Circuit Diagram.............................................................................................................................. 127
6.2.5 Electrical Elements Table ............................................................................................................... 128
6.2.6 Hydraulic Diagram ......................................................................................................................... 129
6.2.7 Hydraulic Elements Table............................................................................................................... 130
6.3 SWE60UF TECHNICAL SPECIFICATION......................................................................................... 131
6.3.1 Machine Specification..................................................................................................................... 131
6.3.2 Boundary Dimension....................................................................................................................... 132
6.3.3 Work Specification .......................................................................................................................... 133
6.3.4 Circuit Diagram.............................................................................................................................. 134
6.3.5 Electrical Elements Table ............................................................................................................... 135
6.3.6 Hydraulic Diagram ......................................................................................................................... 136
6.3.7 Hydraulic Elements Table............................................................................................................... 137
6.4 SWE70B TECHNICAL SPECIFICATION .................................................................................................... 138
6.4.1 Machine Specification..................................................................................................................... 138
6.4.2 Boundary Dimension....................................................................................................................... 139
6.4.3 Work Parameters............................................................................................................................. 140
6.4.4 Circuit Diagram.............................................................................................................................. 141
6.4.5 Electrical Elements table................................................................................................................. 142
6.4.6 Hydraulic Diagram ......................................................................................................................... 143
6.4.7 Hydraulic Elements Table............................................................................................................... 144
6.5 SWE80B TECHNICAL SPECIFICATION ........................................................................................... 145
6.5.1 Machine Specification..................................................................................................................... 145
6.5.2 Boundary Dimension....................................................................................................................... 146
6.5.3 Work Parameters............................................................................................................................. 147
6.5.4 Circuit Diagram.............................................................................................................................. 148
6.5.5 Electrical Elements Table ............................................................................................................... 149
6.5.6 Hydraulic Diagram ......................................................................................................................... 150

VI
6.5.7 Hydraulic component table............................................................................................................. 151
6.6 SWE90UB MACHINE SPECIFICATION ............................................................................................ 152
6.6.1 Machine Specification..................................................................................................................... 152
6.6.2 Boundary Dimension....................................................................................................................... 153
6.6.3 Work Parameters............................................................................................................................. 154
6.6.4 Circuit Diagram.............................................................................................................................. 155
6.6.5 Electrical Elements Table ............................................................................................................... 156
6.6.6 Hydraulic Diagram ......................................................................................................................... 157
6.6.7 Hydraulic Elements Table............................................................................................................... 158
6.7 SWE70F TECHNICAL SPECIFICATION............................................................................................ 159
6.7.1 Machine Specification..................................................................................................................... 159
6.7.2 Boundary Dimension....................................................................................................................... 160
6.7.3 Work Parameters............................................................................................................................. 161
6.7.4 Circuit Diagram.............................................................................................................................. 162
6.7.5 Electrical Elements Table ............................................................................................................... 163
6.7.6 Hydraulic Diagram ......................................................................................................................... 164
6.7.7 Hydraulic Elements Table............................................................................................................... 165
6.8 SWE80F TECHNICAL SPECIFICATION............................................................................................ 166
6.8.1 Machine Specification..................................................................................................................... 166
6.8.2 Boundary Dimension....................................................................................................................... 167
6.8.3 Work Parameters............................................................................................................................. 168
6.8.4 Circuit Diagram.............................................................................................................................. 169
6.8.5 Electrical Elements Table ............................................................................................................... 170
6.8.6 Hydraulic Diagram ......................................................................................................................... 171
6.8.7 Hydraulic Elements Table............................................................................................................... 172
6.9 SWE90UF TECHNICAL SPECIFICATION......................................................................................... 173
6.9.1 Machine Specification..................................................................................................................... 173
6.9.2 Boundary Dimension....................................................................................................................... 174
6.9.3 Work Parameters............................................................................................................................. 175
6.9.4 Circuit Diagram.............................................................................................................................. 176
6.9.5 Electrical Elements Table ............................................................................................................... 177
6.9.6 Hydraulic Diagram ......................................................................................................................... 178
6.9.7 Hydraulic Elements Table............................................................................................................... 179
7. OPERATION INSTRUCTION OF ACCESSORY ................................................................................ 180
7.1 SAFETY ITEMS.................................................................................................................................... 180
7.2 NOTICE FOR ASSEMBLING ATTACHMENT .................................................................................. 180
7.3 HYDRAULIC QUARTERING HAMMER........................................................................................... 181
7.3.1 Main Use of Hydraulic Quartering Hammer.................................................................................. 181
7.3.2 Hydraulic Quartering Hammer Assembly....................................................................................... 181
7.3.3 Hydraulic Quartering Hammer Control ......................................................................................... 182
7.3.4 Safe Operation of Hydraulic Quartering Hammer.......................................................................... 183
7.4 OPTIONAL PARTS LIST...................................................................................................................... 186
8 MANUFACTURE INFORMATION ........................................................................................................ 188

1
1. SAFETY RULES
1.1 SAFETY MARK
Figure 1.1 is the mark to remind of safety, when you see this
mark on the machine or in the manual book; it indicates that the
human body is in danger of injury.
1.2 SAFETY LABEL
There are various labels at various points of machine, in these
labels, various words indicate various hurt risks, such as
―DANGER‖, ―WARNIGN‖, ―CAUTION‖ etc (as right figures),
they means as follows:
DANGER (As figure 1.2.1)—indicates an imminently
hazardous situation which, if not avoided, could result in
death or serious injury.
WARNING (As figure 1.2.2)—indicates a potentially
hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION (As figure 1.2.3)—indicates potentially
hazardous situation which, if not avoided, may result in
minor or moderate injury.
―DANGER‖, ―WARNING‖ safety labels are stuck at given points
of machine within the range of possible danger. General
attentions listed on the ―CAUTION‖ safety label. In this manual
book, ―CAUTION‖ also remind of safety instruction.
1.3GENERAL SAFETY INSTRUCTION
(As figure 1.3)
(1) Study the manual carefully and follow the safety
instructions in the labels and manual before operating
the machine.
The safety instructions in this chapter only
include the general safety rules of machine.
They can‘t cover all the possible dangers. If
there is any problem, please report to your
superior before operation and maintenance.
Figure 1.3
Figure 1.2.1
Figure 1.2.2
Figure 1.2.3

2
(2) Always keep the safety labels clean. Change any lost or damaged label with a new one. If the labels or
manual book lost, you can contact dealer and indicate the model of machine to purchase a new one.
(3) Only qualified operator is permitted to operate this machine. Keep the machine in good condition as per
this manual.
(4) Don‘t refit machine without authorization, otherwise it will affect the performance and service life of
machine, or may cause human body hurt or even death.
1.4 PREPEARE FOR EMERGENCY
All concerned people should be cautions so as to
prevent accident occurring, and at the same time,
deposit first-aid kit and fire extinguisher nearby
(As figure 1.4), and place the phone numbers of
hospital and fire department near telephone to ask
for help in case of emergency.
1.5 WEARING SAFETY PROTECTIVE ARTICLES
Before operation, always wear protective articles when
the work so requires, they include (As figure 1.5):
Skintight work clothes
Hard hat
Safety gloves
Safety glasses, goggles, or veil
Respirator or filtration veil
Earplug or ear cap
1.6 CHECKING MACHINE BEFORE
START-UP
Before start machine every day or every shift, check the machine
according to the contents in ―Check machine before start-up‖ of
this manual.
Figure 1.4
Figure 1.5
Figure 1.7

3
1.7 SEAT ADJUSTMENT
If you use this machine for the first time, or change operator, the operator should adjust seat (As figure 1.7) to
suit himself: back on the seat, the feet can operate the pedals at ease. (Refer to 2.5 seat for details)
1.8 ENTERING OR LEAVING MACHINE
1) Always face the machine when you use the steps and
hand-holds to enter or leave machine (As figure 1.8).
2) Never use any control lever as hand-hold.
3) Never enter or leave machine when the machine
travels, swings, or digs (lifts).
1.9 STARTING ENGINE CORRECTLY
The operator must sit on cab seat to start engine. Not
allow starting engine with the operator standing on
crawler.
Not allow starting engine with short circuit start-up
(including terminal start-up, as figure 1.9).
1.10 FORBID CARRYING PASSENGERS
When the machine is operating or traveling, prohibit other people
except operator staying on the machine (As figure 1.10).
1.11 KEEPING MACHINE AWAY
FROM ELECTRICITY TRANSMISSION
LINE
Any part or load of machine touching electricity
transmission line will cause human death or GBH.
Prohibit machine or its load closing to electricity transmission
line, the machine should be 3 meters away from line (As figure
1.11).
Figure 1.8
Figure 1.9
Figure 1.10
Figure 1.11

4
1.12 MOVING MACHINE SAFELY
1) Before the machine travels and swings, operator should know
the position of other people.
2) When machine travels or before it swings, operator should
warn other people by ringing the horn.
3) Operation at confined area, should use signal in swinging,
and harmonize the hand signal before machine start-up.
4) Before operate the machine traveling, must confirm that the
operation of traveling pedal/control lever should be
corresponding with the traveling direction.
5) Treadle the foreside of traveling pedal or push traveling lever
forward, and the machine will travel along tension wheel. By
contraries, the machine will travel along sprocket wheel.
6) When machine travel on slope, place bucket as figures
showing, keep bucket 200-300mm up the slope ground,
if the machine slides or becomes unstable, set the bucket
down at once(As figure 1.12).
1.13 PREVENTING ACCIDENTS WHILE BACKING OR SWINGING
1) In order to prevent accident while backing or swinging, the
operator must follow:
2) Before back or swing the machine, look round and confirm
nobody is around.
3) Ensure that other people standing out of the boom swing
range.
4) Pay attention to that whether other people stay in work range
or not. Ring horn or use other signal to warn before move the
machine.
5) If the operator‘s vision is blocked when the machine backs, a signalman is needed and the signalman
should always be seen.
6) If signalman needed, the signalman should use hand signal. Only when both signalman and operator
understand the meaning of signal, the operator can operate the machine traveling and swinging (As figure
1.13).
Figure 1.12.1
Figure 1.12.2
Figure 1.13

5
1) Understand all the meanings of flag, mark, and signal, and determine the person who is
in charge of signaling.
2) Keep the cleanness of window, mirror, and lamp.
3) When the visibility weakened by dust, rain, and fog, etc, lamplight should be used.
4) Please read carefully and understand well the contents of this manual book.
1.14 DIGGING SAFELY
1) Before digging work, operator should be aware of the
position of embedded lines, such as cable, gas pipe, water
supply pipe, and operate the machine carefully to prevent
accident.
2) All the non-working people should be away from the working
range of machine.
3) Make sure the ground of working site is hard enough to
support machine (As figure 1.14.1).
4) When the machine works at pithead, the tension wheel end
should be outward pithead, keeping the traveling orientation
vertical with pit cliff. In this way, the machine can move
away easily when the cliff collapses.
5) When the machine works in the deep, it should prevent the
boom bottom and cylinder from colliding with high objects.
6) Turn over prevention
7) When the machine works on slope, the track should park along the slope, retract the bucket as much as
possible, keep the bucket close to ground and machine, to avoid turning over (As figure 1.14.2).
When swing with load, it must decrease swing speed to avoid turning over. When working on frozen
ground, it should prevent the ascending temperature from causing the ground to soften; otherwise it
will affect the stability of machine.
7) During operation, prevent boom or arm from colliding with high objects.
8) The bucket only for digging work, not allow using bucket to work as pneumatic pick or hydraulic breaker
does.
1.15 AVOID MACHINE UNCONTROLLED
When the machine loses control, if someone tries
Figure 1.14.1
Figure 1.14.2

6
to mount on or stop moving machine, it will cause
GBH or death (As figure 1.15.1).
To avoid the machine losing control, pay attention to the
following proceedings:
Place the machine on horizontal ground, try your best
not to stay on slope, and stop machine as following
procedures:
Lower the bucket to the ground.
Run engine at low revs for 3 minutes to cool down machine.
Stop engine, take out key from key switch.
Switch off pilot control.
If the machine has to stay on slope, use chocks to block crawler, lower bucket, and plug bucket teeth into ground.
Fix the machine well to avoid accidental movement.
Park the machine away from other machines for proper distance.
1.16 PARKING MACHINE SAFELY
Stop machine as following schedule (As figure 1.16):
Place machine on horizontal ground.
Lower the bucket to the ground.
Run engine at low rev for 3 minutes.
Place the timing handle at stop position, screw the
ignition key to ―OFF‖ position.
Switch off pilot control.
Close window, top window, and cabin.
1.17 SAFE MAINTENANCE
1) Attention of maintenance:
Before work, be aware of maintenance rules.
Keep the working area clean and dry.
Power switch
Figure 1.15.1
Figure 1.16

7
Don‘t allow inject lubricant or maintain to moving machine.
Avoid body and clothing touching with transmission parts.
2) Preparation for maintenance
Place the machine on horizontal ground.
Lower the bucket to the ground.
Run engine at low rev for 5 minutes.
Pull stop handle forward, stop engine, take out key from the
switch.
Hang the ―DO NOT OPERATE‖ label at control lever (As figure 1.17.1).
Switch off pilot control.
3) Safety in maintenance
If the maintenance must be made during the engine operation, there must be somebody in cabin.
If the machine must be lifted, the angle between boom and arm must be kept between 90-110°, to support the
lifted parts stably in maintenance work (As figure 1.17.2).
Never work under the machine being lifted by boom.
Check some parts in regular interval, and repair or replace, if
necessary. (refer to the chapter ―maintenance‖ of this
manual)
Make sure all parts are in good condition and fitted correctly.
Replace wearing or damaged parts. Clean any accumulative
lubricant or scraps.
When adjust electric system or weld on machine, disconnect grounding cable (-) of battery.
1.18 SUPPORTING MACHINE SAFELY
1) Prohibit repairing or maintaining machine before the machine well supported.
2) Before maintenance, lower the work device to the ground.
3) If the machine or work device have to be lifted for maintenance purpose, the machine or work device
should be well supported.
4) Don‘t support the machine on the slag, hollow brick, or other fragile objects.
5) Don‘t work under machine when the machine only supported by a jack.
Figure 1.17.1
Figure 1.17.2

8
1.19 CLEANING TRASH ON THE MACHINE
1) Keep the engine, radiator, battery, hydraulic line, fuel tank,
and cabin clean.
2) After stopping engine, the surrounding temperature may rise
immediately (As figure 1.19). Open overhaul gate to cool
engine as soon as possible and clean engine apartment.
3) Clean machine at regular interval, eliminate accumulative
lubricant and other trash. Make sure not to spray water or
vapour into cabin.
1.20 PREVENTING BATTERY FROM EXPLODING
1) Prohibit fire or flame close to the battery top, otherwise the
battery gas will explode (As figure 1.20).
2) Check the electricity deposit with voltage meter or gravimeter.
Don‘t place metal bestriding connection rod to check
electricity deposit.
3) Never electricize the frozen battery, otherwise it will explode.
The battery should be warmed up to 16°C(60°F).
1.21 STORING PARTS SAFELY
1) The stored parts, such as bucket, hydraulic breaker, etc, are likely to fall down, causing GBH or death.
2) By all effective means, store parts and machine safely to prevent falling down. Don‘t permit unauthorized
people, especially children, closing to the parts storage area.
1.22 PREVENTING SPLASH OBJECTS
1) Prevent splash metal or grits hurt, wear blinkers or safety glass
(As figure 1.22).
2) Before knock on object, check whether somebody else is
in the working area or not, and stop other people
entering in the working area to avoid hurt.
1.23 PREVENTING FLYING-OFF PARTS
In operation or maintenance, take care of the parts that may fly off, human body and face must avoid the
Figure 1.19
Figure 1.20
Figure 1.22

9
possible flying off parts.
1.24 AWAY FROM TRANSMISSION PARTS
1) Touching transmission parts may cause GBH.
2) When work around the transmission parts, in order to avoid
accident, prevent hand, foot, hair and clothes from entangling
in the machine (As figure 1.24).
1.25 PREVENTING ASBESTOS DUST
INHALATION
1) Prevent inhaling possible asbestos dust (As figure 1.25), for the
asbestos fiber may cause lung cancer.
2) Some washers contain asbestos fiber, in these components,
normally, the asbestos is in the resin or enveloped in some way.
If the asbestos-contained parts don‘t bring dust, there isn‘t danger in normal disposal.
3) To avoid causing dust, don‘t clean with compressed air, and
avoid brushing and grinding asbestos-contained materials. In
maintenance work, please wear regulated respirator, use special
dust collector to clean asbestos. If can‘t get this dust collector,
use little oil or water to bemoisten asbestos-contained material.
Comply with working area rules and concerned asbestos
disposal rules, stop other people entering in working area.
1.26 BEWARE OF FOG OR GAS INHALATION
1) Inhale engine exhaust gas will cause disease, so much as, or
death.
2) If it is necessary to operate machine in the building, should
open door and window to ensure well ventilation, or use long
exhaust pipe to discharge smoke (As figure 1.26).
1.27 BEWARE OF SCALDING
1) During operation, engine oil, gear oil, hydraulic oil will
become hot. Meanwhile, engine, hose, pipeline, and
Figure 1.24
Figure 1.25
Figure 1.26
Figure 1.27

10
other parts will also become hot. Beware of scald (As
figure 1.27).
2) Carry out inspection and maintenance after oil and parts
are cooled to prevent scald. The hydraulic oil tank and
pipeline are high pressured, before maintenance or
replacement, it should release the pressure to avoid hot
oil erupting.
1.28 BE CAREFUL TO PRESSURE LIQUIDS
1) Effluent liquids in high pressure will penetrate through skin,
causing GBH (As figure 1.28.1).
2) Release pressure before disjoining liquids or other
pipeline to avoid this danger. Operate control lever
many times to release pressure.
3) Before supercharging, tighten all the connections.
4) Inspect leakage with cardboard, make sure to protect
your hand and body against touching high pressure
liquids (As figure 1.28.2).
5) If accident occurs, see the doctor at once.
6) Any liquid penetrated in skin must be cleaned within few
hours. Otherwise it will cause necrosis.
1.29 NO HEATING NEAR PRESSURE OIL PIPE
1) If heating near pressure oil pipe, the inflammable spray will cause
severe burn to nearly people. Don‘t carry out welding, gas
protection welding, or gas cutting near pressure oil pipe or other
flammable goods.
2) If it is a must to carry out welding, gas protection
welding, or gas cutting near pressure oil pipe, it should
mount temporary fireproof jacket to protect hose or other
materials (As figure 1.29).
1.30 NO HEATING INFLAMMABLE LIQUID
PIPE
Not permit to weld inflammable liquid steel pipe or hose. Before
Figure 1.28.1
Figure 1.28.2
Figure 1.29
Figure 1.31

11
welding this kind of pipe or hose, clean this pipe or hose completely with incombustible solvent.
1.31 ATTENTION ON WELDING & POLISHING
The welding should be carried out on the ventilation area as for it may cause gas and fire.
Before welding, please put the flammable objects to the safety place.
Only the licensed operators are allowed to weld. It's stictly forbidden to weld by unlicensed workers.
Put the flammable objects to a safety place before polishing which may cause sparks.
Make sure there's no spark, smoke or any other abnormal at the working area and the surrounding after
finishing welding and polishing.
1.32 REMOVING PAIN BEFORE WELDING OR HEATING
Prevent bringing potential poisonous gas and dust.
When paint heated up by welding or other methods, it will cause poisonous gas.
Remove paint as following methods before welding or heating up.
Rub out paint with abrasive paper or wheel, during this work, remember to wear regulated respirator
to prevent inhaling dust (As figure 1.31).
Rub out paint with solvent or paint remover. After rubbing out, clean paint remover with soap and
water before welding. Before welding or heating up, volatilize the paint remover gas at least 15
minutes.
The paint removing work should be operated at outdoor or well ventilation site.
1.33 NOTES FOR WELDING ON MACHINE EQUIPPED WITH
ELECTRONIC CONTROLLER AND ENGINE
The welding procedures should be strictly followed Welding Technical Universal Guidelines to avoid damage
of electronic controlling devices and bearings. Before welding, dismantle the parts which need to be weld from
the machine if possible. If it's inevitable to weld on the machine, please disassemble the electronic controlling
device from the machine before that. The following steps should be obeyed.
Shut down the engine and turn the starting switch to OFF position.
Turn the battery switch to OFF position, if there's no such switch, dismantle the negative cable of the
battery. All connection plug of the main engine and the products with controller including the electronical
controlling engine should be pulled out.
The wiretapping of the electric welding machine connect the welding parts loacally and fastenly.(Note:
Don't use the ground point of the electric parts or electrical parts as the ground point of electric welding
machine.) Make sure the sealed parts or bearing and other connection parts are not be connected by the
electricity from welding wiretapping to the welding position. Besides, it's forbidden to use the pin shaft of
work device, the ground point of electrical parts or the surrounding area of hydraulic cylinder as the
connecting zero point. Otherwise, it may damage the hydraulic parts, electrical parts and transmission

12
parts.
Clean off the wires, diesel tubes, hydraulic pipeline, oil and sundries within one meter area of welding
parts. Insulation block should be taken to those unmovable and can't be elimated things. Take high
temperature protection measures for welding parts to avoid the efficiency losing of parts and fire caused
by high temp.
Pay attention to the damage of glasses and surrounding parts caused by fly-out and clean it off at once.
While welding on the key structure positions, it's necessary to take reasonable welding scheme to prevent
structure damage from welding transfromation.
It's not allowed to weld oil tank, cylidner, air bottle without professional safety measurements.
1.34 DISPOSING LIQUID SAFELY
1) All fuels, majority of lubricants, and some coolants are inflammable.
These inflammable liquids should be stored away from fire, not
permitted to stab or set storage case on fire.
2) Dispose fuel carefully, stop engine before adding fuel, and prohibit
smoking while adding fuel or using flame near the machine being
added fuel. Add fuel at outdoor site.
3) Don‘t put oil-containing rags on the machine to ensure machine
clean.
1.35 DISPOSING CHEMICAL SAFELY
Touching deleterious chemical directly will cause serious injury to human body. The chemical using in
excavator, such as lubricant, coolant, dope, and adhesive, may be deleterious.
Before using deleterious chemical, you should check and understand its danger, know how to operate safely,
and use recommended implement to work.
1.36 PREVENTING FIRE
In order to avoid fire, following methods are necessary (As figure
1.34).
Check the leakage, the leakage of fuel, hydraulic oil and
lubricant may cause fire.
Inspect clamps whether lost, damaged or loosened or not, hose
twisted or not, attrition between hose and hard pipe or not, oil cooler
damaged or not, and oil cooler connection loosened or not. Use a
piece of cardboard to check leakage, never check leakage with nude
Figure 1.34

13
hand to prevent pressured oil shooting up causing injury.
Tighten, repair, or replace any clamps, pipe, hose, oil cooler, and flange bolt of oil cooler.
Don‘t twist or knock on high-pressured pipe.
Don‘t assemble twisted or damaged pipeline or hose.
Inspect short circuit. The short circuit of electric system can cause fire.
Before every shift or 8 hours operation, check loosened, twisted, hardened, or cracked cable and wire.
Before every shift or 8 hours operation, check lost or damaged connectors.
Before operation, tighten, repair, or replace any loosened or damaged cable, wire and connector. If the cable or
wire is loosened or twisted, don‘t operate the machine.
Repair switch
Before everyday operation, check the function of key switch and engine emergency stop switch. If there is any
unusuality, must repair at once. In case of fire, if you can‘t stop engine, it will aggravate firepower, and may
cause GBH.
Clean out inflammable materials
Spilled fuel, stored breeze, and other inflammable materials, may cause
fire. Keep the machine clean every day to prevent fire.
1.37 EMERGENCY EXIT
Emergency exit mark (As figure 1.35.1):
When there is an emergency and the operator can not get out of the cabin, take the small hammer (As figure
1.35.2) hung on the wall in cabin to break the window with emergency exit mark to leave the machine. The
cabin safety structure can not be repaired after damage but it can be replaced with other qualified safety
protective structures.
(1) Pay attention not to be hurt by the splashing objects while breaking the
window with a certain distance to the breaking hole for safety.
(2) The breaking hole should be big enough for operator to get out
(according to operator’s own condition) and the hole should have no
sharp spines for safety.
Figure 1.35.1
Figure 1.35.2