swl3210 Servisnyij Manual

Service Manual
Product for the world
SKID-STEER LOADER
HUNAN SUNWARD INTELLIGENT MACHINERY CO., LTD.
SWL3210 Service Manual
INDEX
1 INTRODUCTION ....................................................................................................................................... 4
1.1 MODELS AVAILABLE...................................................................................................................... 4
1.2 ABOUT THIS MANUAL .................................................................................................................... 4
1.3 TREATMENT OF THIS MANUAL.................................................................................................... 4
1.4 UNITS .................................................................................................................................................. 4
1.5 DEFINITION OF “LEFT” SIDE AND “RIGHT” SIDE ...................................................................... 4
1.6 PRECONDITION TO USE THE MACHINE ...................................................................................... 5
1.7 SIGNALS................................................................................................................................................ 5
2 SECURITY.................................................................................................................................................. 7
2.1 MEANING OF THE SAFETY SIGNS ................................................................................................ 7
2.1.1 GENERAL SIGNS ....................................................................................................................... 7
2.1.2 ACOUSTIC SIGNS.................................................................................................................... 10
2.2 LOCATION OF THE SAFETY LABELS ......................................................................................... 11
2.3 GENERAL PREVENTION ............................................................................................................... 11
2.3.1 GENERAL SAFETY RULES.................................................................................................... 11
2.3.2 CLOTHING AND PERSONAL PROTECTION....................................................................... 12
2.3.3 ENTER AND LEAVE THE MACHINE ................................................................................... 12
2.3.4 PREVENTION OF FIRE TO FUEL AND OIL ......................................................................... 13
2.3.5 PREVENTION OF BURNS....................................................................................................... 14
2.3.6 PREVENTION OF DAMAGE OF WORKING EQUIPMENT ................................................ 14
2.3.7 PREVENTION OF ELECTRIC SHOCK................................................................................... 14
2.3.8 LIMITS OF THE MACHINE .................................................................................................... 15
2.4 MAINTENANCE PREVENTION..................................................................................................... 15
2.4.1 GENERAL RULES .................................................................................................................... 15
2.4.2 RUNNING THE ENGINE DURING THE MAINTENANCE.................................................. 16
2.4.3 WORKING UNDER THE WORKING EQUIPMENT AND MACHINE ................................ 16
2.4.4 SAFETY RULES FOR HIGH-PRESSURE OIL AND HOSE .................................................. 17
2.4.5 PREVENTION ON THE STARTER AND ALTERNATOR.................................................... 17
2.4.6 PREVENTION OF BATTERY HAZARD ................................................................................ 17
2.4.7 PRECAUTION DURING INFLATING THE TIRES ............................................................... 18
3 GENERAL DESCRIPTION OF THE MACHINE ................................................................................... 19
3.1 DESCRIPTION OF THE MACHINE ................................................................................................ 19
3.1.1 FRONT VIEW............................................................................................................................ 19
3.1.2 REAR VIEW .............................................................................................................................. 19
3.1.3 MACHINE DISTRIBUTION..................................................................................................... 20
3.2 SPECIFICATION .............................................................................................................................. 21
3.2.1 GENERAL DATA ..................................................................................................................... 21
3.2.2 OVERALL DIMENSION .......................................................................................................... 21
3.2.3 ENGINE ..................................................................................................................................... 22
3.2.4 ELECTRIC SYSTEM ................................................................................................................ 22
3.2.5 PNEUMATIC............................................................................................................................. 23
3.2.6 OILS AND COOLANT.............................................................................................................. 23
3.2.7 CAPACITIES ............................................................................................................................. 23
3.2.8 TORQUE FOR SCREWS .......................................................................................................... 24
3.2.9 LUBRICATION POINTS .......................................................................................................... 25
4 HYDRAULIC SYSTEM ........................................................................................................................... 26
4.1 MAIN TRAVEL PUMP ..................................................................................................................... 26
4.1.1 ILLUSTRATION OF MAIN TRAVEL PUMP COMPONENTS ............................................. 26
4.1.2 PIPELINE CONNECTION (FOR TESTING) OF MAIN TRAVEL PUMP............................. 30
4.1.3 SET PRESSURE DATA FOR MAIN TRAVEL PUMP ........................................................... 31
4.2 TRAVEL MOTOR............................................................................................................................. 33
4.2.1 ILLUSTRATION OF TRAVEL MOTOR MAIN COMPONENTS......................................... 33
4.2.2 PICTURE OF BRAKE OIL PIPES’ CONNECTION................................................................ 35
4.2.3 ROTATION DIRECTION OF TRAVEL MOTOR. ................................................................. 35
4.2.4 PRESSURE FOR ARRESTING GEAR’S START ................................................................... 35
4.3 WORKING REAR PUMP ................................................................................................................. 36
1
4.3.1 OUTSIDE VIEW OF GEAR PUMP .......................................................................................... 36

4.3.2 BREAKDOWN DRAWING OF GEAR PUMP ........................................................................ 37
4.3.3 MANIFOLD VALVE................................................................................................................. 37
4.3.4 OUTSIDE VIEW AND ILLUSTRATION OF MANIFOLD VALVE...................................... 37
4.3.5 SET THE DATA ........................................................................................................................ 38
4.4 BUCKET-LIFT VALVE.................................................................................................................... 39
4.4.1 THE OUTLINE AND ILLUSTRATION OF BUCKET-LIFT VALVE.................................... 39
4.5 LARGE FLOW CONTROL BLOCK (ONLY FOR LARGE FLOW SYSTEM)................................................. 41
4.5.1 OUTSIDE VIEW AND ILLUSTRATION OF LARGE FLOW CONTROL BLOCK.............. 41
4.5.2 SET THE DATA ........................................................................................................................ 42
4.5.3 OPERATING HANDLE ............................................................................................................ 42
4.5.4 OUTSIDE VIEW AND DATA OF HAND LEVER.................................................................. 42
4.6 PEDAL OPERATION VALVE ......................................................................................................... 48
4.7 HYDRAULIC DIAGRAM ................................................................................................................ 49
5 ELECTRICAL SYSTEM .......................................................................................................................... 50
5.1 INSTALLATION SITE 1.......................................................................................................................... 50
5.2 INSTALLATION SITE 2.......................................................................................................................... 51
5.3 DIAGRAM ............................................................................................................................................ 52
5.4 CIRCUIT DIAGRAM .............................................................................................................................. 54
5.4.1 POWER AND ENGINE CIRCUIT............................................................................................ 54
5.4.2 Safety and protection of circuit................................................................................................... 60
5.4.3 MONITOR CIRCUIT................................................................................................................. 63
5.4.4 LAMP AND FLOAT CONTROL CIRCUIT ............................................................................. 65
5.4.5 OPTION CIRCUIT..................................................................................................................... 67
6 TRAVEL SYSTEM................................................................................................................................... 68
6.1 TRAVEL SYSTEM COMPONENT....................................................................................................... 68
6.1.1 WHEEL SHAFT......................................................................................................................... 69
6.2 POWER TRAIN MAINTENANCE ............................................................................................................. 71
6.2.1 REMOVAL OF THE FRONT WHEEL SHAFT AND REAR WHEEL SHAFT ..................... 71
6.2.2 CLEANING AND INSPECTION .............................................................................................. 75
6.2.3 REPAIR OR REPLACEMENT ................................................................................................. 75
6.2.4 INSTALLATION ....................................................................................................................... 75
7 MAINTENANCE ...................................................................................................................................... 77
7.1 REQUIREMENT SERVICE.............................................................................................................. 77
7.2 ADVICE FOR THE MAINTENANCE.............................................................................................. 77
7.3 DESCRIPTION FOR MACHINE MAINTENANCE ........................................................................ 78
7.3.1 ENGINE DESCRIPTION .......................................................................................................... 78
7.3.2 SAFETY BELT .......................................................................................................................... 78
7.4 MAINTENANCE PLAN ................................................................................................................... 79
7.4.1 BEFORE STARTING ................................................................................................................ 82
7.4.1.1 CHECKING ENGINE OIL LEVEL ...............................................................................................................82
7.4.1.2 CHECKING ENGINE COOLANT LEVEL...................................................................................................82
7.4.1.3 CHECKING ENGINE FUEL LEVEL..................................................................................................................82
7.4.1.3 CHECKING THE HYDRAULIC OIL LEVEL..............................................................................................82
7.4.1.4 CHECKING THE ELECTRIC CABLES .......................................................................................................82
7.4.1.5 CHECKING THE TIRES ...............................................................................................................................83
7.4.1.6 CHECKING THE SAFETY BELT ................................................................................................................83
7.4.1.7 CHECKING THE LEAKING OF OIL ...........................................................................................................83
7.4.1.8 CHECKING THE QUICK COUPLER...........................................................................................................83
7.4.1.10 ECKING THE WATER AND SEDIMENTS SEPARATOR.............................................................................83
7.4.2 EVERY 50 HOURS OF OPERATION...................................................................................... 83
7.4.2.1 CHECKING THE COOLER PIPES.....................................................................................................................83
7.4.2.2 CHECKING THE COOLANT LEVEL..........................................................................................................84
7.4.2.3 CHECKING THE TIRE PRESSURE.............................................................................................................84
7.4.2.4 GREASING THE PINS OF BOOM AND CYLINDERS ..............................................................................84
7.4.2.5 CHECKING THE WHEEL NUT DRIVING TORQUE.................................................................................84
7.4.3 EVERY 100 HOURS OF OPERATION .......................................................................................... 84
7.4.3.1 CLEANING THE TERMINALS OF THE BATTERY........................................................................................84
7.4.3.2 CLEANING THE OIL TANK’S BREATHER ....................................................................................................84
7.4.3.3 CHECKING THE CYLINDER RODS ................................................................................................................84
7.4.3.4 GREASING ALL OF PINS..................................................................................................................................85
2
7.4.4 VERY 250 HOURS OF OPERATION ............................................................................................ 85

7.4.4.1 CHECKING THE GEARING CHAIN TENSION...............................................................................................85
7.4.4.2 ADJUSTING THE CHAIN IF NECESSARY......................................................................................................85
7.4.4.3 CHECKING THE FAN BELT .............................................................................................................................85
7.4.4.4 CLEANING THE RADIATOR............................................................................................................................85
7.4.4.5 CHECKING THE OIL LEVEL IN THE GEAR CHAIN.....................................................................................85
7.4.4.6 CHANGING THE ENGINE OIL .........................................................................................................................86
7.4.4.7 CHANGING THE ENGINE OIL FILTER...........................................................................................................86
7.4.4.8 CHANGING THE FUEL FILTER .......................................................................................................................86
7.4.4.9 CHECKING THE NUT TORQUE OF THE HYDARULIC MOTOR AND THE HUB HOLDING TO THE
CHASSIS..........................................................................................................................................................................87
7.4.5 EVERY 500 HOURS OF OPERATION .......................................................................................... 88
7.4.5.1 CLAEN THE FUEL-WATER SEPARATOR......................................................................................................88
7.4.5.2 CHECK THE TIGHTENESS OF PUMP FIXING SCREWS ..............................................................................88
7.4.5.3 CHECKING THE FLUID LEVEL OF THE BATTERY.....................................................................................88
7.4.5.4 CHANGING THE HYDRAULIC OIL FILTER ..................................................................................................89
7.4.6 EVERY 1000 HOURS OF OPERATION.................................................................................. 89
7.4.6.1 CHANGING THE OIL IN THE GEAR CHAIN BOX...................................................................................89
7.4.6.2 CHANGING THE HYDARULIC OIL AND CLEAN THE SUCTION ........................................................89
7.4.6.3 CHANGING THE AIR FILTER ....................................................................................................................90
7.4.6.4 CHECKING THE PUMP’S PRESSURE AND THE VALVE.......................................................................91
7.4.6.5 CHANGING THE HYDRAULIC OIL TANK BREATHER.........................................................................91
7.4.6.6 CHECKING THE TIGHTNESS OF THE CYLINDER HEAD SCREW.......................................................91
7.4.6.7 CHECKING THE LOOSENESS OF THE VALVE.......................................................................................91
7.4.7 EVERY 2000 HOURS OF OPERATION.................................................................................. 92
7.4.7.1 CHANGING THE COOLANT.......................................................................................................................92
7.4.7.2 CHECKING THE STARTER AND ALTERNATOR....................................................................................92
7.4.8 WHEN REQUIRED ......................................................................................................................... 92
7.4.8.1 DRAINING THE FUEL TANK ...........................................................................................................................92
7.4.9 TROUBLE SHOOTING................................................................................................................... 93
8 INFORMATION OF MANUFACTURER ................................................................................................... 97
3
1 INTRODUCTION
1.1 MODELS AVAILABLE
This manual is special for the SWL series skid-steer loader. A series of skid-steer loaders
“SWL” are developed by HUNAN SUNWARD INTELLIGENT MACHINERY CO., HUNAN
SUNWARD INTELLIGENT MACHINERY CO., LTD own all intelligence property related to
this machine.
1.2 ABOUT THIS MANUAL
This manual contents all the information about the SWL machine. The safety regulations,
description, service and maintenance instructions are included in this manual. HUNAN
SUNWARD INTELLIGENT MACHINERY CO., LTD supply this manual together with the
spare parts book. He provide the user all information
related to the SWL skid-steer loader and all safety
regulations.
For more information, please contact your SWL dealer.
The dealer knows how to get the best performance of
the machine and how to use the machine correctly in
any case.
1.3 TREATMENT OF THIS MANUAL
This operation and maintenance manual must be
handled with great care and always kept in the machine,
so that the operator can consult it at any moment. There is a compartment special for operation
manual and spare parts inside cabin. It locates on the behind of the seat. See the right picture.
The operation manual must be always kept in this case.
In case of damage or lose this manual, request to HUNAN SUNWARD INTELLIGENT
MACHINERY CO., LTD or the SWL dealers for a new one.
1.4 UNITS
In this manual we have taken the international unit system. We are using millimeter for distance,
liter for volume, degree for angle, etc.
ITEM UNIT SYMBOL
Distance Millimeter mm
Volume Liter L
Angle Degree °
Temperature Celsius degree °C
Sound Decibel dB
1.5 DEFINITION OF “LEFT” SIDE AND “RIGHT” SIDE

In this manual, “left” and “right” imply your left hand side and right hand side when you are
seated properly in the machine. It is also showed in the picture below.
4
1.6 PRECONDITION TO USE THE MACHINE

z To maintain this skid-steer loader properly and safely, operator must know well about this
machine and have basic experience on using this kind of machine.
z The operator must take special attention on the security recommendation in order to
preserve his security and the security of persons around him.
z Do not work with the machine until you are sure that you can control it properly. Do not
begin a work until you are sure there is no danger for you and for people around you.
z If you have any doubt regarding the safety regulations, please contact your SWL dealer.
1.7 SIGNALS
To help you to maintain machine safely, we have described many safety precautions in this
manual. Also many precaution labels are put on the machine. Many different signal words are
used in the manual and on the labels.
The following signal words are used to inform you that there is a potential hazardous situation
that may lead to personal injury and damage. In this manual and on the precaution labels on the
machine, the following signal words are used to express the level of the potential hazardous.
If not avoided, it has great possibility to lead to serious

injuries or death to the operator (or other persons). It is used
to express the most extreme dangerous situation.
If not avoided, this situation could cause serious injuries

even death.
5
If not avoided, this situation may cause minor or moderate

injury to operator (or other persons) or damage to the
machine.
There are other signal words showed under to indicate precautions that are useful for operator.
It is used for precautions that must be taken to avoid actions

what could shorten the life of the machine.
It is used for information that is extremely useful to know.
The safety message may not include all the possible safety precautions. It is impossible to
describe all the potential hazard may appear during the operation or maintenance. For any
question regarding the safety regulation please contact your dealer.
6
2 SECURITY
This section describes the possible hazards that may appear during the operation and
maintenance of the machine. Authorized additional equipments have their manual given
together with the equipments.
2.1 MEANING OF THE SAFETY SIGNS
Safety precaution labels are fixed to the machine to warn about possible hazards that may cause
personal injuries or even death. They are placed where the possible danger is. Before using the
machine make sure you understand all the security labels. Keep all the labels clean and readable.
Change all the damaged labels.
2.1.1 GENERAL SIGNS
The following table shows the different labels fixed on the machine and the respective meanings.
GENERAL LABELS
Moving crawlers, when Entanglements in can

cause serious injury
High temperature
See manual book
7
Note
Float
Tail warning
Oil level
Diesel Oil
8
Oil filter
Drag position
Lifting points
Operation direction
Operation direction
Safety pin for boom
9
Security button
Emergency exit
Engine hood
2.1.2 ACOUSTIC SIGNS

The following table shows the different acoustic labels fixed on the machine and the respective
meaning.
ACOUSTIC LABELS
The max noisy level out of cabin.
The max noisy level in cabin.
10
2.2 LOCATION OF THE SAFETY LABELS

The safety labels were located in striking position.
2.3 GENERAL PREVENTION
2.3.1 GENERAL SAFETY RULES
The following items are extremely important. Operators must read with great care and follow
them while operating and performing maintenance.
z Only authorized and experienced personnel can use or maintain the machine.
z The using and maintenance must be taken follow with the safety rules describe in this
manual.
z Use the machine only when the machine is in good operating condition.
z Don’t use the machine for the tasks exceed its capacity.
z Operate the machine only when the operator is seated correctly in the driving position.
z Before do any maintenance, position the machine on a firm and level surface, lower
working equipments to the ground, engage the safety lock of working equipment, stop the
engine.
z It is forbidden to modify the connections and safety settings of the hydraulic system. Before
do any modification, please consult your dealer. Any unauthorized modification may lead to
serious injury to operator or damage to the machine. HUNAN SUNWARD
INTELLIGENT MACHINERY CO., LTD will not take the responsibility to the result
caused by this kind of unauthorized modification.
z Install only authorized auxiliary equipments. Any additional equipment more than the
authorized auxiliary equipments list in this manual may not perform well even cause
damage to the machine and injury to persons. See the list of authorized auxiliary
equipments.
z Before travel on the road, make sure the lights, signaling and safety device are in good
condition and engage relative safety devices.
z Do not use the machine before read and understand this manual. Any inappropriate use of
this machine could be very dangerous for the operator and the person around the machine.
Many of the accident are caused by insufficient knowledge of the safety regulations
described in this manual.
z It is extremely dangerous operate the machine under the effect of alcohol or drugs. Do not
take alcohol, medicine what makes you sleepy or drugs before or during use the machine.
11
2.3.2 CLOTHING AND PERSONAL PROTECTION
z Inappropriate clothing may lead to injury to the

operator. Please wear in the protective clothing while
operating or performing maintenance such as hardhat,
goggles glasses, mask gloves, safety shoes and
headphones.
z If you have long hair, tie up them before approach the
machine since they can get entangled in the moving
part of the machine and cause serious injuries and
damage.
z When working for 8 hours with a noise exceeding 90
dB, it is necessary to use headphones.
z When working in a special dangerous area, additional
protections could be required according to the
conditions.
2.3.3 ENTER AND LEAVE THE MACHINE
Use the appropriate footplates and handles showed in the following picture while entering and
leaving the machine.。
z Enter and leave the machine only when the machine is not moving unless it is in
emergency.
z Never hold on the joysticks.
z Use always the appropriate handles while entering and leaving the machine.
z Always be carefully while entering and leaving the machine. Keep your body balance
during the whole processes of entering and leaving the machine.
12
z Before enter and leave the machine, make sure the footplate and handles are not covered
with oil, grease, ice or other slippery matter. In case it happens, clean the slippery matter
carefully immediately.
z Take great care in case the machine is wet. It could be very slippery.
Before leave machine, carry out the following procedures in the sequence.
1) Park the machine in a safe position.

2) Lower the working equipment to the ground.
3) Engage the parking brake.
4) Engage the auxiliary equipment control pedal retainer.
5) Raise the restrain bar to upward.
6) Stop the engine.
2.3.4 PREVENTION OF FIRE TO FUEL AND OIL
z Fuel and oil are easily to cause fire if they meet flame.
z Keep always flame away from the fuel and oil.
z Stop the engine and never smoke during refueling.
z Only do the refilling fuel and oil in the well ventilated areas.
z Close well the safety cap after charge or fuel.
z Do not fill the tanks in order to leave room for the fuel expansion.
z If some fuel or oil is spilled wipe it up immediately.
13
2.3.5 PREVENTION OF BURNS

z After operating for a period, the engine, coolant,
hydraulic oil, engine oil, radiator and pumps are
hot. Do not touch them until they cool down.
z In case of entailing working with hot oil, hot
coolant or hot hydraulic oil, wear gloves, heavy
clothing and safety goggles before do any check
or maintenance.
z Loosen the coolant safety cap slowly when the
coolant is hot to release the residual pressure
inside the tank before open it. If it is hot it may
spurt out and cause serious burns.
z Before checking the coolant level, the hydraulic
oil level and the engine oil level, stop the engine
and wait till they cool down.
2.3.6 PREVENTION OF DAMAGE OF WORKING
EQUIPMENT
z Do not stand in the area that the working
equipment can reach when the machine is operating. It may cause serious injury or even
death.
z Before perform working equipments, the
operator must make sure that nobody is in the
dangerous area that working equipment can
reach.
z Try to lower the working equipment to the
ground every time when you park the machine.
z During maintenance, make sure the equipment is locked correctly before go into the
area under lifted working equipment.
2.3.7 PREVENTION OF ELECTRIC SHOCK
Voltage of Cables (kV) 1.0 6.6 33 66 154 275
Distance must be kept (m) 5.0 5.2 5.5 6.0 8.0 10.0
14
z Do not travel or operate the machine near the electrical cables. On the working sites
where the machine may go close to electrical cables, follow the procedures below.
Otherwise it is possible to get an electric shock, which may cause serious injury even
death.
z Before starting working near the electrical cables,
consult the power company what is the voltage
with the cables and inform the power company
of your coming work. If necessary, ask them to
take actions.
z To prepare for any possible emergencies, wear
rubber shoes and gloves. Prepare all things you
need to call the power company immediately in
case of accident.
z Even going close to the high-voltage cables can cause electric shock. Always maintain a
safe distance (see the table up) from the cables.
z Use a signalman to give warning if the machine approached too close to the electrical
cables.
z If the machine come too close to or entangled with the electrical cables, do not leave the
cabin and let any person approach the machine until the electricity has been shut off.
2.3.8 LIMITS OF THE MACHINE
z This machine has been designed for one operator. More than one passenger on the
machine can be extremely dangerous. Never transport more than one passenger with this
machine.
z Overload could cause serious injuries or even death. Never overload the machine. For
the detail capacity of machine, please refer the section of specification in this manual.
Do not try to get a better efficiency of the
machine by doing any unauthorized change.
2.4 MAINTENANCE PREVENTION
2.4.1 GENERAL RULES
z To do any maintenance position the machine on a
firm and flat surface, rest the equipments on the
ground, engage the security locks, apply the
parking brake and stop the engine. If necessary,
put wedges under wheels to fix the machine.
Before doing the maintenance, place the warning tag
“DO NOT OPERATE” to the joysticks and ignition
switch. Make sure nobody other who is not doing
maintenance together with you operate the machine while
you doing maintenance.
z Only authorized and duly trained personnel can
do the service and repair. Only do the
maintenance that you are certain. If you have any
question, please consult the dealers.
15
z Keep the machine and the ambient clean. Keep the parts and tools in proper place.
z To prevent pollution, never deposit the fuel, oil and grease directly onto the ground. Use
containers to keep the fuel, oil and grease and drain them according to the local
regulations.
WRONG
2.4.2 RUNNING THE ENGINE DURING THE MAINTENANCE

z If the maintenance must be carried out with
engine running, two workers are necessary. One
worker must always seat in the operator’s seat
and be ready to stop the engine at any time.
z Keep the safety lock in function during the
maintenance operations.
z When the engine is running, don’t touch the
rotating parts. The rotating parts like fan and fan
belt are extremely dangerous because they can
make you get caught. Be careful not to come
close to them.
2.4.3 WORKING UNDER THE WORKING EQUIPMENT AND MACHINE
z If it is necessary to carry out service and

maintenance under the working equipment or the
machine, support the equipment and machine
with block and stands strong enough to support
the weight of the working equipment and
machine.
z Lower the working equipment to the ground or the lowest position before working
under the machine.
16
2.4.4 SAFETY RULES FOR HIGH-PRESSURE OIL AND HOSE

z The hydraulic system is always under internal pressure. Before do any inspecting or
replacing hoses, always lower the working equipment and make sure that the pressure in
the hydraulic circuit has been released.
z The high-pressure oil leakage from small holes can penetrate your skin or injury your
eyes. Extreme care must be taken when you are inspecting high-pressure oil leakage.
Wear goggles and thick gloves. Use a piece of cardboard to check oil leakage instead of
your hands.
z Damaged hoses could be extremely dangerous and could cause serious injuries. Change
the damaged hoses and connections as soon as possible.
z If you are hit by a jet of high-pressure oil and suffer injury to your skin and eyes, wash
your skin and eyes with clean water and consult a doctor immediately.
WRONG RIGHT
2.4.5 PREVENTION ON THE STARTER AND

ALTERNATOR CONNECT
z Before doing any check on the electric circuit,
disconnect the battery in order to cut off the
current.
z If some electrical welding has to be done on the
machine, it is necessary to disconnect the battery
and also the alternator.
z Never try to start the engine by manipulating the
connexions of the starter. It will cause sudden machine move. It is very dangerous for
the operators.
2.4.6 PREVENTION OF BATTERY HAZARD
Battery electrolyte contains sulphuric acid and generates flammable hydrogen gas. The
sulphuric acid is extremely harmful to your body.
Solutions for the accidents:
1) If the electrolyte contact your eyes flush them immediately with plenty water and
contact a doctor immediately. Acid could cause blindness.
2) If some electrolyte contact with your skin, wash immediately with plenty water.
3) If accidentally you ingest some acid, drink a large quantity of milk, eaten eggs or
vegetable oil and call immediately a doctor.
Please always follow with the following precautions:
17
z Always wear goggles and gloves when you are working with the battery.
z Stop the engine and remove the key before
working on the battery.
z Never smoke and use any flame near the battery.
z Always tighten the terminals and caps securely.
Loosen terminals or caps may cause fire and
explosion.
z Do not let tools other metal objects make any
contact between battery terminal.
z Disconnect first the negative earth cable (-) and then the other positive cable (+).When
connecting, connect fist the positive cable (+) and then the negative earth cable (-).
z If there is a welding operating on the machine, please disconnect the battery cables
before it.
DISCONNECT
2.4.7 PRECAUTION DURING INFLATING THE
TIRES
• Take into consideration that tires can burst while
being inflating. Inflate the tires bit by bit.
• For inflating the tires use an air-compressing gun
with extension and a gauge for control the
pressure in the tire.
• Do the maintenance of the tires like described in
the relating item of this manual.
• Do not stand very close to the tire during inflating
the tire and make sure that nobody stands close.
• Follow the recommendation for the pressure
given in the related item of this manual. Make
sure that the tire pressure is the same on both
sides of the machine.
18
3 GENERAL DESCRIPTION OF THE MACHINE

3.1 DESCRIPTION OF THE MACHINE
3.1.1 FRONT VIEW
3.1.2 REAR VIEW
19
3.1.3 MACHINE DISTRIBUTION
3 4
5
2
6
1
7
10
1. Bucket 2.Working lamp

3. Cabin 4.Hydraulic oil tank
5. Engine hood 6. Fuel tank
7. Arm 8. Wheel
9. Exhaust pipe 10. Rear cover
20
3.2 SPECIFICATION
3.2.1 GENERAL DATA
ITEM SWL 3210
Operating weight 3250kg
Nominal load 950kg
Tipping Load 1900kg
Bucket volume 0.53m3
Breakout force (lifting cylinder) 2420Kgf
Breakout force (tilting cylinder) 2470Kgf
Max traveling speed 12.6Km/h
3.2.2 OVERALL DIMENSION
21
Item Specification SWL3210

A Overall operating height 4020 ㎜
B Height to bucket hinge pin 3123 ㎜
C Height to top of cab 2100 ㎜
D Height to bottom of level bucket 2950 ㎜
E Overall length without attachment 2750 ㎜
F Overall length with standard bucket 3590 ㎜
G Dump angle at maximum height 43°
H Dump height 2395 ㎜
J Reach at maximum height 625 ㎜
K Rollback of bucket on ground 30°
L Rollback of bucket at full height 93°
M Wheelbase 1116 ㎜
P Bottom of belly pan 205 ㎜
Q Angle of departure 27°
R Clearance circle front without bucket 1300 ㎜
S Clearance circle front 2180 ㎜
T Clearance circle rear 1700 ㎜
U Rear axle to bumper 1062 ㎜
V Tread width, centerline to centerline 1475 ㎜
W Width with excavating bucket 1880 ㎜
3.2.3 ENGINE
ITEM KUBOTA V3300DI
POWER OUTPUT 54.9Kw

MAX TORQUE 244N-m
ROTATION 2600rpm
3.2.4 ELECTRIC SYSTEM

ITEM SWL 3210
Battery 80Ah or 100Ah
Alternator 12V-45A
Starter motor 12V-3.0A
22
System voltage 12V

Current total 25A
3.2.5 PNEUMATIC
ITEM Pressure
10X16.5 PR10 CHAOYANG 60PSI
12X16.5 PR10 CHAOYANG 60PSI
10X16.5 PR10 MECHILIN 65PSI
12X16.5 PR10 MECHILIN 65PSI
10X16.5 PR10 SOLIDEAL 65PSI
12X16.5 PR10 SOLIDEAL 65PSI
3.2.6 OILS AND COOLANT
z Use only oil and coolant recommended in this manual.
z Use different oils could reduce the efficiency of the machine or even damage the
machine.
OILS, COOLANT AND FUELS SPECIFICATION
Hydraulic Oil TOTAL AZOLLA ZS46,

MOBIL AW46
Engine Oil MOBIL DELVAC1330,
ESSO LUBE D-3 10W 30
Engine Coolant TOTAL MULTIS EP2,
ESSO BEACON EP2
Travelling Mechanism Oil TOTAL AZOLLA ZS46,
MOBIL AW46
Fuel Diesel Fuel 0#
z Do not mix different kind of oils. If you have oil different from the current oil,
remove all the oil inside the machine.
3.2.7 CAPACITIES
ITEMS CAPACITY (Litre)
Model SWL3210
Hydraulic oil tank 65
Hydraulic system
100
(Pipes+Tank+Cylinders)
Engine coolant 3.5
Engine oil 13.2
Fuel tank 85
Travelling Mechanism 2X15
23
3.2.8 TORQUE FOR SCREWS

Unless other specification, tighten the nuts and bolts according to the torques shown in the
below table. Tighten the goods by the wrenches with gauge.
Thread Diameter (mm) Quality 8.8 Torque (Nm) Quality 10.9 Torque (Nm)
M6 9~12 13~16
M8 22~30 30~36
M 10 45~59 65~78
M 12 78~104 110~130
M 14 124~165 180~210
M 16 193~257 280~330
M 18 264~354 380~450
M 20 376~502 540~650
M 22 512~683 740~880
M 24 651~868 940~1120
M 27 952~1269 1400~1650
M 30 1293~1723 1700~2000
When tighten parts of the machine made by steel be careful to not tighten it too strong,
since you could damage this parts.
24
3.2.9 LUBRICATION POINTS

The following drawing shows the main lubrication points.
25
4 HYDRAULIC SYSTEM
4.1 MAIN TRAVEL PUMP
4.1.1 ILLUSTRATION OF MAIN TRAVEL PUMP COMPONENTS
Front pump X2 X1 Y X1 X2 Rear pump
DA VALVE
Charge pump
G1 S
26
Port G2 of
charge pump
Port B of
rear pump Port A of Port A of front Port B of front
rear pump pump pump
Relief valve of Relief valve of

rear pump port B rear pump port A
Relief valve of Relief valve of

Relief valve of
front pump port front pump
charge pump
B port A
27
Test port MB of Port G Test port MB of Port T

rear pump B front pump B
Test port G
Test port MA Test port MA of

of front pump rear pump A
A
28
Bolt of max
displacement of Zero displacement
front pump, A point adjustment
output of front pump
Zero displacement
point adjustment
of rear pump
Bolt of max
displacement
of rear pump,
A port output
Bolt of max Bolt of max

displacement of displacement of
rear pump, B port front pump, B port
output output
29
4.1.2 PIPELINE CONNECTION (FOR TESTING) OF MAIN TRAVEL PUMP
30
4.1.3 SET PRESSURE DATA FOR MAIN TRAVEL PUMP
Pay attention to the following items before the assembly of testing tools:
Lift up the boom, start safety rod, get the cabin upside down and insert safety pin.
Release the pressure of the system and that inside of the other components until the
hydraulic oil has cooled down to normal temperature .
Hydraulic testing tools:
Two manometers: one with its measurement range of 60MPa(600ar), the other one with its
measurement range of 6MPa(60bar)
※Rated engine rev: 2800±50rpm（for SWL28）or 2600±50rpm(forSWL32)
※Engine idle speed: 1000±50rpm
1） Pressure setting for charge pump
When leaving factory, the pressure for charge pump is 25±2bar. When testing its pressure, place
a manometer with its measurement range of 6MPa on G test port.（screw thread for oil port：
9/16-18NUF-2B）. The charge overflow valve ② can not be adjusted by screw rod, therefore,
the pressure change can only be achieved by disassembling the valve to add or reduce the
spacers.
2) Pressure setting for travel startup
For the sake of safety, when engine rev is less than 1300rpm, the machine traveling mechanism
can not work. If abnormality occurs, take the following steps to check pressure data: place a
testing tool with a manometer whose measurement range is 6Mpa in the pipeline of port Y. Then
start the engine and set its rev at 1300±50rp. The pressure showed on the manometer now
31
should be about 6bar. If any deviation occurs, adjust the valve DA⑥ and correct it. When the
engine rev is more than 2600rpm，the outlet pressure of port Y should be more than 18bar.
3）When leaving factory, the pressure for traveling pump’ s main front and rear oil ports A and
B is 325±5bar. Before testing their pressure, place a manometer whose measurement range is
60MPa in test ports MA and MB.（screw thread for oil port：9/16-18NUF-2B）. When it’s
necessary to change the pressure of main oil overflow valve, disassemble the valve and adjust its
screw rod.
4）Adjust the zero displacement of variable cylinder
If the machine travels while hand lever is on neutral position, or if it travels in deviation when
operating hand lever, check whether the variable cylinder is right on “zero” position. If not,
adjust it by centering screw rod.
5）Adjust the max displacement of variable cylinder
When leaving factory, the oil pump’s displacement is set at 46ml/r (the max. one). If machine
travels in deviation when hand lever is on the position of max. operation range, the output
volume of two oil pumps is likely to be different, which can be adjusted by max. displacement
limitation screw.
32
4.2 TRAVEL MOTOR

4.2.1 ILLUSTRATION OF TRAVEL MOTOR MAIN COMPONENTS
Right travel motor Left travel motor
Port Z for
opening brake Port L for Port A
Port B leakage output
33
Solenoid operated
Oil supply
direction valve for
port for
control brake
brake
Pilot oil supply Pilot oil supply port

port for working for travel
34
4.2.2 PICTURE OF BRAKE OIL PIPES’ CONNECTION
4.2.3 ROTATION DIRECTION OF TRAVEL MOTOR.

When port A begins to suck oil, it seems from the shaft end that the motor runs clockwise; when
port B begins to suck oil, it seems from the shaft end that the motor runs anticlockwise.
4.2.4 PRESSURE FOR ARRESTING GEAR’S START
An often –closed brake is set at the end of motor. When starting the brake, the min. pressure is
15bar. The pressure for this system is supplied by travel charge pump (25bar) and controlled by
pilot oil sources magnet valve. When abnormality of brake oil pipeline occurs, a manometer
whose measurement range is 60bar is to be placed in the pipeline , to check whether the pressure
is normal and whether the magnet-valve can carry out control as requested. Then resolve the
malfunction.
35
4.3 WORKING REAR PUMP

4.3.1 OUTSIDE VIEW OF GEAR PUMP
Gear pump 1 Suction port Gear pump 2
36
4.3.2 BREAKDOWN DRAWING OF GEAR PUMP

See the appendage
4.3.3 MANIFOLD VALVE
4.3.4 OUTSIDE VIEW AND ILLUSTRATION OF MANIFOLD VALVE
Main relief
valve Boom Bucket Auxiliary
37
4.3.5 SET THE DATA

The main overflow valve① of manifold valve determines system’s working pressure. The
working pressure for this system is set at 210±10BAR, while the pressure for second overflow
valves ②③ is set at 235±10bar. When manifold valve is used in large flow system, take away
the plug ④, install a transition connector to channel hydraulic oil to large flow control block.
38
4.4 BUCKET-LIFT VALVE

4.4.1 THE OUTLINE AND ILLUSTRATION OF BUCKET-LIFT VALVE
39
40
4.5 LARGE FLOW CONTROL BLOCK (ONLY FOR LARGE FLOW SYSTEM)
OUTSIDE VIEW AND ILLUSTRATION OF LARGE FLOW CONTROL
4.5.1
BLOCK
Solenoid operated
Testing
direction valve for Safety valve for
fitting
control summation summation
41
4.5.2 SET THE DATA

Place a manometer whose measurement range is 60MPa in connector for pressure test.（screw
thread ： M16X2 ） The pressure for this device can be set by adjusting safety valve. The
pressure is set at 210bar when leaving factory.
4.5.3 OPERATING HANDLE
4.5.4 OUTSIDE VIEW AND DATA OF HAND LEVER
3
2
4
P
1
T
42
43
WORING HAND LEVER NOZZLE TABLE:

handle oil port Multiunit valve pilot port
1 V1
3 V2
2 V4
4 V3
P PH(pilot oil sources block
44
Outside view and data of travel hand lever
C g
FF
E
P T
45
46
Signal port
47
TRAVEL HAND LEVER CONNECTION：

Hand lever oil port Travel pump pilot port
C Front pump X1
D Rear pump X1
E Front pump X2
F Rear pump X2
g Signal connector for machine reversing
P PV(pilot oil sources block)
4.6 PEDAL OPERATION VALVE
1 2 P T
48
4.7 HYDRAULIC DIAGRAM
PEDAL VALVE NOZZLE TABLE：

Pedal valve oil port Multiunit valve oil port
1 V5
2 V6
P PH(pilot oil sources block)
49
5 ELECTRICAL SYSTEM
5.1 INSTALLATION SITE 1
4 1 11 12 13 14 14 15 6 8
2 2
3 5 10 3
1. Head work lamp 2.Head small lamp 3.Rear work lamp 4.Horn 5.Rear lamp
6. Enable switch 7. Fuses box 8.Start switch 9.Reversing horn 10.Beacon lamp
11.Water temperature meter 12.Hour meter 13. Fuel gauge 14.Indicators
15. Switch-group
50
5.2 INSTALLATION SITE 2
3 5 6 7 8 9 10
1 2
1. Battery 2.Alternator 3.Starter 4. Disconnect switch (Option)

5.Air heater(Preheating) 6.Relay box 7.Pressure switch 8.Fuel pump 9.Air filter
10.Stop solenoid valve
51
5.3 DIAGRAM
Code Name and function

SQ2 Seat switch
SP1,SP2 Travel pressure switch
SP3 Brake pressure switch
SP4 Reversing pressure switch
L1~L5 Outline light
L6~L7 Head work lamp
L8~L9 Rear work lamp
L10~L11 Parking brake light
L12~L13 Turning light
L14 Beacon lamp
DL Horn
SA0 Start switch
SA1 Working device switch
SA2 Beacon lamp switch
SA3 Clearance light /Head work lamp switch
SA4 Rear work lamp switch
SA5 Left Turning Light switch
SA6 Right Turning Light switch
SA7 Wiper switch
SA8 Warm air conditioner switch
SA9 High flow switch
S0 Enable switch
HL0 Enable switch lamp
S1 Disconnect switch
S2 Horn switch
S3 Boom float switch
S4 Washing switch
TR1 Water temperature sensor
TR2 Fuel sensor
TR3 Oil pressure sensor
52

K1 Start relay
K2 Protect relay
K3 Fast pull relay
K4 Delay relay
K5 Safety relay
K6 Pilot relay
K7~K8 Invert relay
K9 Brake indication relay
K10 Parking lamp relay
K11 Horn relay
K12 Flasher
K13~K14 Float relay
HL1 Brake indication lamp
T1 Delay module
XP Maintainance power
DL1 Reversing horn
R0 Air heater
R1~R4 Resistance
D1~D7 Diode
HL0 Enable switch lamp
P1 Water temperature meter
P2 Fuel gauge
P3 Hour meter
E1~E8 Alarm lamp
TR5 Air filter sensor
TR6 Hydraulic oil filter sensor
53

BAT Battery 12V
G1 Alternator
M1 Starter
F00 Main fuse
F01 Starting fuse
F02 Fast pull fuse
F0 Start switch fuse
F1 Safety switch fuse
F2 Meter fuse
F3 Clearance light fuse
F4 Head work lamp fuse
F5 Rear work lamp fuse
F6 Parking brake light fuse
F7 Horn fuse
F8 Float valve fuse
F9 Turning light fuse
F10 Beacon lamp fuse
F11 High flow valve fuse
F12 Warm air conditioner fuse
F13 Wiper fuse
M2 Wiper motor
M3 Washing motor
M4 Warm air conditioner
M01 Fuel pump
Y0 Fuel Valve
Y1 Pilot valve
Y2 Parking brake
Y3 Working device valve
Y4 Boom float valve
Y5 High flow valve
EDU Indicators
SQ1 Safety-bar switch
5.4 CIRCUIT DIAGRAM
5.4.1 POWER AND ENGINE CIRCUIT
1. Power circuit
The cathode of battery is grounded through engine and chassis.
54
There are a mechanical type switch S1 on the battery(+)，the battery switch is always on the
“ON” position when the machine is in operation.
When the ignition lock switch is on the “OFF” position, the current flows from the a battery
anode as shown below：
z Battery + →disconnect switch S1→ main fuse F00 →
z Check point
→Ignition lock switch (B)

→Alarm lamp fuse F10→Alarm lamp switch SA2 →Alarm lamp L14→ GND
→maintenance power XP → GND
→High flow valve fuse F11→high flow switch SA9→high flow valve Y5→ GND
Ignition
Disconnect
Engine lock Check point Voltage
switch
switch
①battery + - GND
②fuse - GND DC10~14.5
OFF OFF ON
③switch - GND V
④solenoid valve - GND
※GND：Ground
※Disconnect switch S1, maintenance power XP, high flow switch SA9, high flow valve Y5
are assembled as options.
※ ATTENTION: When starting, the large displacement switch must be on the “ON”
position, otherwise, the engine can not be started because of the large load.
2. Starting circuit
1) YANMAR diesel engine（SWL28）
Battery + →disconnect switch S1
Start switch position : ON →alternator (IG)

Start switch ON(Br)→ignition →Stop solenoid valve Y0(hold-on
→starter (B+) solenoid)→GND
lock switch fuse F0
→main fuse F00→start
→Fuelswitch (B)
pump M01→GND
→Delay module T1 (solenoid) →GND
Battery + →disconnect switch S1→fast pull Fuse
F02→fast pull relay K3(normal open) →Stop solenoid Y0(start solenoid )→GND
z Start switch position : START
Start switch START(C) →relay K2 (normal close) → start relay K1 solenoid →GND
battery + →disconnect switch S1→start Fuse F01→relay K1(normal open)→starter
(ST)→GND
z Start switch position: PRE-HEAT
55
Start switch PRE-HEAT (R1) → preheater R0→GND

2) KUBOTA diesel engine（SWL32）
Battery + →disconnect switch S1
Start switch ON (Br) → ignition lock switch Fuse F0 →Stop solenoid Y0(hold-on
solenoid)→GND
→Fuel pump M0→GND
Start switch position: ON
z Start switch position : START
Start switch START(C)

→ Relay K2(normal close) →start relay K1 solenoid →GND
→Stop solenoid Y0 (start solenoid ) →GND
→Preheating delay module T1→GND
→starter (B+)
Battery + →disconnect switch S1→start fuse
F01→start relay K1 normal open →main fuseF00 →start switch (B) →starter
(ST)→GND
Battery + →disconnect switch S1→main fuse F00→preheating delay module T1→air heater
R0→GND
z Start switch position: PRE-HEAT
Start switch PRE-HEAT (R1)→preheating delay module T1→GND
Battery + →disconnect switch S1→main fuse F00→preheating delay module T1→air heater
R0→GND
3) Check point
Start Disconnect
Engine Check point Voltage
switch switch
①battery + - GND
②fuse - GND
③start switch - GND DC10~14.
Operating START ON
④delay module - GND 5V
⑤relay - GND
⑥air heater - GND
GND：Ground
Disconnect switch S1 is assembled as an option.
Attention:
※ Do not operate the starter lock on the “START” position for more than 30
seconds。
56
※ Do not operate starter lock switch on the “START” position after the machine is
started.
DANGER: Do not disconnect or shorten any lead wire while the starter is operating.
3. Charging circuit
Operator releases the start lock switch from the “START” position to the “ON” position after
the machine is started.
Charging current generated by the operating alternator flows into the battery, it also flows from
the alternator to each electrical component.
1) Circuit flow
⑴Charging circuit
Alternator B
→disconnect switch S1→battery +
→main Fuse F00→start switch B
→alarm lamp fuse F10
→high flow valve fuse F11
⑵ Charging alarm circuit

When the machine is not yet started and the ignition lock is on the “ON” position, generator
does not make electricity, so the indicator light for charge is on. After the machine is started,
generator starts to make electricity, so the indicator light for charge is off.
Start switch on the “ON” position → start switch ACC →instruments fuse F2 →charging
indicator light E2 →alternator (L)
2) Check point
Start Disconnect
switch switch
①battery + to GND
②fuse to GND
③alternator B to GND DC10~14.
Operating START ON
5V
④alternator IG to GND
⑤charging indicator light E2
to GND
GND：Ground
Disconnect switch S1 is assembled as an option
z When using an arc welder, always cutoff disconnect main switch to avoid
damaging the alternator and battery.
z Attach the welder ground clamp as close to the weld area as possible to avoid
damaging the bearings of the alternator from welding current.
z Do not disconnect the battery when the engine is running. The voltage surges can
damage the diode and resistors of the electrical system.
z Stop the engine and ensure the switch on the “OFF” position before cutting off the
electric wire.
57
Power and engine circuit -------YANMAR（SWL28）
58
Power and engine circuit -------KUBOTA engine（SWL32）
59
5.4.2 Safety and protection of circuit

1) Safety circuit
For the sake of safety, two interlockers i.e. seat switch and safety bar switch are installed. Only
when operator sits correctly, and gets the safety bar ready, the machine is likely to travel or do
other tasks.
Circuit flow
Start switch position ON → start switch ACC →Safety Switch Fuse F1→
→safety relay K5（normal close）→safety light E7 →GND

→safety bar switch SQ1→GND
→delay relay K4（ solenoid ）→Seat switch SQ2→GND
→safety bar switch SQ1→delay relay K4（delay point）→safety relay K5→GND
2) Parking brake protection circuit

When safety interlockers are closed, brake parking system will be opened.
Start switch position ON → start switch ACC → Safety switch fuse F1→relay K9 (normal close)
→ parking brake light HL0→GND
● First push brake switch S0，circuit flow：
Safety Switch Fuse F1→safety relay K5（normal open）→
→Brake switch S0(1)→Pilot relay K6（ solenoid )→GND

→relay K6 (normal open) or S0 (1) →
→Resistance R2→relay K7 (normal open) → Brake switch S0 (2) →GND

→Resistance R1→relay K8 (solenoid) →diode D1→Enable switch S0 (2)→ GND
→diode D2→relay K8（normal open）→GND
→Resistance R2→relay K7( solenoid )→diode D2→relay K8（normal open）→GND
→Pilot solenoid valve Y1→GND
→Door limit switch SQ3→working device switch SA1→working device valve Y3→GND
→Brake valve Y2→diode D7→relay K8(normal open)→GND
Safety Switch Fuse F1→relay K9( solenoid ) →relay K8（normal open）→GND

z Push the brake switch S0 again，circuit flow：
Safety Switch Fuse F1→safety relay K5（normal open）→
60
→Brake switch S0(1)→Pilot relay K6（ solenoid ）→GND

→Relay K6 (normal open) or S0 (1) →Resistance R1→relay K7(normal open)→S0(1) →GND
→Pilot solenoid valve Y1→GND
→Door limit switch SQ3→working device switch
SA1→working device valve Y3→GND
Safety switch fuse F1→relay K9 (normal close)→ Parking brake lightHL0→GND
3) Check point
Start Disconnect
switch switch
①fuse - GND
Operating/ DC10~14.5
ON ON ②relay - GND
OFF V
③solenoid valve - GND
GND：Ground
z Do not disconnect the battery when the engine is running. The voltage surges can
damage the diode and resistors of the electrical system.
z Stop the engine and ensure the switch on the “OFF” position before cutting off the
electric wire.
61
Safety protection circuit
62
5.4.3 MONITOR CIRCUIT

1) Circuit flow
Start switch position ON →start switch ACC →safety switch fuse F2→
→Water temperature meter P1→water temperature sensor TR1→GND
→GND
→Fuel gauge P2 →fuel sensor TR2→GND
→GND
→Hour meter →GND
→Water alarm lamp E1→Water temperature sensor TR1→GND
→Oil pressure alarm lamp E3→oil pressure sensor TR3→GND
→Brake alarm lamp E4→pressure switch SP3→GND
→Air filter lamp E5→air filter sensor TR5→GND
Left (right) turning light switch →diode D5 (D6) → turning lamp E8→GND
2) Check point
Start Disconnect
switch switch
①fuse - GND
Operatin DC10~14.
ON ON ②instrument - GND
g/OFF 5V
③alarm light - GND
GND：Ground
Do not disconnect the battery when the engine is running. The voltage surges can damage
diodes and resistors of the electrical system.
63
Monitor circuit
64
5.4.4 LAMP AND FLOAT CONTROL CIRCUIT

1) Circuit flow
Start switch position ON →start switch ACC→
→Safety switch fuse F3→outline light switch SA3 (I step) →outline light L1~L5→GND
→Safety switch fuse F4→outline light switch SA3 (II step)→Head work lamp
L6~L7→GND
→Safety switch fuse F5→rear work lamp switch SA4→Rear work lamp L8~L9→GND
→Safety switch fuse F6→parking brake light relay K10 (solenoid)→ pressure switch
SP1&SP2→GND
→parking brake light relay K10(normal open)→parking brake light
L10~L11→GND
→safety switch fuse F7 →horn relay K11 (solenoid) → horn switch S1→GND
→horn relay K11 (normal open) →horn DL→GND
→safety switch fuse F9 →flasher K12 (solenoid) →GND
→flasher K12→left (right)Turning Light switch
SA5(SA6)→left(right)Turning Light 12(E13)
Float control circuit:
→Safety switch fuse F8→Resistance R4 →relay K13(normal close)→float switch S3→GND

→relay K13(solenoid)→diode D4→relay
K14(normal open)→GND
→Resistance R3→relay K14(solenoid) →diode D3→float switch
S3→GND
→diode D4→relay
K14(normal
open)→GND
→float valve Y4→relay K14(normal open)→GND
● Fist push float switch S3，Circuit flow：
● Push float switch S3 again，circuit flow：
→safety switch fuse F8→resistance R3→relay K13(normal open)→float switch S3→GND
2) Check point
Engine Start Disconnect Check point Voltage
switch switch
①fuse -GND
Operating/ ②relay -GND DC10~14.
ON ON
OFF ③switch -GND 5V
④light -GND
GND：Ground
65
Lamp and float control circuit
66
5.4.5 OPTION CIRCUIT

1) Circuit flow
→Fuse F13 →wiper switch SA7 (I,II step) →wiper controller →wiper motor M2
→washing switch S4→wiper controller→ washing motor M3→GND
→pressure switch SP3→reversing horn DL1→GND
→fuse F12→warm air conditioner switch SA8 (I,II step)→warm air conditioner M4→GND
Start switch position ON → start switch ACC→

2) Check point
Start Disconnect
switch switch
①fuse-GND
Operating/ ②wiper controller -GND DC10~14.5
ON ON
OFF ③switch -GND V
④motor-GND
GND：Ground
Wiper controller, wiper motor M2, Washing motorM3, Warm air conditioner M4 are assembled
as options for closed cabin.
Pressure switch SP3, reversing horn DL1 are assembled as an option.
Option circuit
67
6 TRAVEL SYSTEM
6.1 TRAVEL SYSTEM COMPONENT
TRAVEL SYSTEM
POS. COD. PART NAME 名称 QTY REMARK
1 730250000041 MOTOR 马达 1
2 302030000728 RUBBER PAD 橡胶垫 1
3 701427016001 NUT 螺母 8
4 701504016003 WASHER 垫圈 16
5 701103016048 BOLT 螺栓 8
6 750313000014 CHAIN 链条 2
7 701427014001 NUT 螺母 20
8 701519014001 WASHER 垫圈 20
9 814341000000 WHEEL SHAFT ASSY 前轮轴总成 1
10 814341000000 WHEEL SHAFT ASSY 后轮轴总成 1
68
6.1.1 WHEEL SHAFT
REAR WHEEL SHAFT

1 814341020000 WHEEL SHAFT 轮轴 1
2 730653000013 GASKET 骨架油封 1
3 702104065002 BEARING 圆锥滚子轴承 2
4 814341010000 WHEEL SHAFT 轮轴支座 1
5 301020000025 O-RING O 形圈 1
6 306060000003 CHAIN WHEEL 链轮 1
7 305070000011 CUSHION 调整垫 1
8 305030000011 PRESS PLATE 压板 1
9 701501016003 WASHER 垫圈 1
10 701103016023 BOLT 螺栓 1
11 751104000013 BOLT 滚花螺栓 10
69
FRONT WHEEL SHAFT

1 814341020000 WHEEL SHAFT 轮轴 1
2 730653000013 GASKET 骨架油封 1
3 702104065002 BEARING 圆锥滚子轴承 2
4 814341010000 WHEEL SHAFT 轮轴支座 1
5 301020000025 O-RING O 形圈 1
6 306060000003 CHAIN WHEEL 链轮 1
7 305070000011 CUSHION 调整垫 1
8 305030000011 PRESS PLATE 压板 1
9 701501016003 WASHER 垫圈 1
10 701103016023 BOLT 螺栓 1
11 751104000013 BOLT 滚花螺栓 10
Notice: the different between the front chain wheel and the rear chain wheel is the direction of
the boss. the boss of front chain wheel direction is inside. the boss of rear chain wheel direction
is outside.
70
6.2 POWER TRAIN MAINTENANCE

6.2.1 REMOVAL OF THE FRONT WHEEL SHAFT AND REAR WHEEL SHAFT
a. Clean the area of dirt and debris.

b. Block the loader securely with four wheels clear
of the ground.
c. Remove the belly pan.

d. Remove the wheels on the side of the machine
that the travel motor is to be removed on.
Oil discharge outlet

e. Remove the final drive lubricating oil drain plug
at the front of the final drive housing and allow the
oil to drain completely.
71
f. Loose the lock nut, untie the chain wheel.
g. Remove the axles.
h. Remove the chain wheel of the axle.
72
i. Remove the bearing of the axle.
j. Remove the shift of the axle.
K. Remove and discard oil seal.
73
l. Remove the shaft of the axle.
m. Remove the outer bearing cups with an inside

bearing puller or brass punch. Be careful if using
the brass punch.
n. Clean the gears bearing cones and cups in a

cleaning solvent．
2) Inspect the bearing cones and cups for flat
areas，pitting，scoring and other damage．
3) Inspect the gears for flat areas pitting， Scoring
and other damage．
74
6.2.2 CLEANING AND INSPECTION

1) Clean the gears， bearing cones and cups in a cleaning solvent．
2) Inspect the bearing cones and cups for flat areas， pitting， scoring and other damage．
3) Inspect the gears for flat areas， pitting， Scoring and other damage．
6.2.3 REPAIR OR REPLACEMENT
1) Replace the gears if they are pitted， scored or damaged．
2) Replace bearing cones and cups if they have flat areas, are pitted， scored or damaged．
If a bearing cone or cup is damaged, both parts must be replaced at the same time.
6.2.4 INSTALLATION
1) Shrink-fit bearing cups into the housing by refrigerating or cooling before pressing them into
place．
2) Lubricate the new oil seal and install with part number facing the flange end of the axle on
the seal surface of the axle．
3) Heat or press the outer axle bearing cone into the axle Be sure the bearing is fully seated．
※If the bearing cone is heated use an induction type heater (Hot plate) ．
4) When the bearing is cooled pack it with Multipurpose lithium bass grease．
5) Fill oil into the front and rear axle housing．
Lubricate chain
wheel lubricating
oil level to the
oil hole bottom
6) Install the axle assembly in the housing．

7) Pack the inner bearing cone with bearing
grease．
75
8) Reach through the inspection cover opening and install the inner bearing cone on the axle.
Make sure it is seated properly in the cup．
9) Reach through the inspection cover opening and install and sprocket on the axle． The hub
end of the sprocket must face the flange end of the axle．
10) Place a bolt through the hole in the axle flange to prevent the axle from turning．
11) apply a gasket sealer to the outside of seal．
12) Install washer and nut．
13) Torque nut is close to 761bf．ft(1 03Nm) possible without backing off the nut to align the
split pin holes．
Do not back off the nut．
1 4) Install a split pin through torque nut．
15) Secure the inspection cover and gasket to the final drive housing with four nuts．
76
7 MAINTENANCE
7.1 REQUIREMENT SERVICE
The machine has been designed and manufactured for giving the maximum autonomy with a
minimum of maintenance. Before selling the machine SUNWARD has tested the machine to
ensure an optimum working of the machine. To keep the machine in good working it is
recommended to do maintenance program as described in this manual. In the following items it
is described how to do the maintenance and in which intervals. For maintaining the efficiency of
the machine it is recommended that only specialized person from SUNWARD SERVICE do the
maintenance task, since they have the necessary tools to do the maintenance correctly and
securely. All the services done to the machine has to be registered in a register table given with
the machine. Only stuff from SUNWARD has the capacity to fill up the register table.
7.2 ADVICE FOR THE MAINTENANCE
z Keep the machine always clean and tidy. It makes much easier to find out troubles.
z Follow the recommendations given in the section 2 “security” to ensure your security and
the security of the people around you.
z Before opening the engine hood, make sure all the security devices are engaged and the
engine is stopped.
z Lower the boom and bucket to the ground when you need to check the hydraulic system.
z Apply the parking brake when going out from the machine.
z Raise the cabin following the recommendation .
z Always use the recommended oil and grease given in this manual.
z Before carrying out any maintenance, put warning plate for sure that nobody switches on
the machine.
z Make sure you carry out the maintenance in a secure and flat place.
z Check and change the oil in a clean place to prevent dust or impurities getting into the tank.
z Wait after the hydraulic oil cools down to do any maintenance work.
z Never use flammable fluids to clean the machine.
z Never spray high pressure to the radiator, since it can damage it.
z Never spray water directly inside the cabin, since you can wet the electric system
connectors or wetting the ignition switch.
z When working in dusty environment, check air filter, radiator, filters and electric
components more often than usual.
z Take care before using the machine in mud or rainy weather to carry out a general
lubrication. Clean the machine immediately after work under damp conditions in order to
protect the different components from rust.
z Use the oil recommended in this manual. Use of another kind of oil could damage the
machine. It is recommended not to mix the oil of different brands, neither to top up oil of
different levels.
z Follow the current regulation for throwing out oils, filters, coolants and batteries, since they
can damage the environment.
z Avoid the skin contacting with used oil since it could irritate it. If your eyes get in contact
with oil, clear your eyes with plenty water and if discomfort persists, contact a doctor. In
case of ingesting oil accidentally, contact as soon as possible a doctor.
77
7.3 DESCRIPTION FOR MACHINE MAINTENANCE

The following items describe different machines’ parts and systems for a better understanding of
doing the maintenance. This manual tries to go deeper in these parts or system that needs more
attention in the maintenance.
7.3.1 ENGINE DESCRIPTION
This section describes or gives some advice about the engine. For deeper information about the
engine, consult the engine manual which should be given together with this manual.
z The engine can be considered as the heart of the machine, so it needs a special attention.
z Take special care with the engine oil, since a good lubrication can extend the life of the
engine.
z Use only oil recommended in this manual.
z Coolant containing antifreeze is flammable. Never contact this type of coolant with a flame.
z Use only coolant recommended in this manual. Never use any other coolant, since it could
damage the rubber couplings.
z Take special care of the engine fuel, since a wrong fuel may damage the engine.
z Do not refill the tank fully, since it is recommendable to leave enough space for the
expansion of fuel.
z When the fuel runs out or when the fuel filter has to be changed, the pipes needs to be
drained.
z The fuel tank is located in the backside of the machine and has a capacity of 70L for
SWL2810, 85L for SWL3210.
z Change all of fuel supply pipes every 2 years or 4000 hours (whichever occurs first).
7.3.2 SAFETY BELT
z Change the seat belt every 4 years.
z Check the situation of seat belt frequently.
78
7.4 MAINTENANCE PLAN

A maintenance plan has been described in this manual in order to maintain the efficiency of the
machine and his parts. It is recommendable to follow this plan. Be aware of the working hours
by reading the hour meter.
Write down all the maintenance assistance done to the machine in order to do a proper
maintenance plan. The maintenance has to carry out by authorized and qualified persons.
The following table summarizes the entire maintenance plan.
TASKS BS 50 100 250 500 1000 2000 WR
7.4.1.1 CHECKING ENGINE OIL

X
LEVEL
7.4.1.2 CHECKING ENGINE
X
COOLANT LEVEL
7.4.1.3 CHECKING FUEL LEVEL X
7.4.1.4 CHECKING HYDRAULIC OIL
X
LEVEL
7.4.1.5 CHECKING THE ELECTRIC
X
CABLES
7.4.1.6 CHECKING THE TIRES X
7.4.1.7 CHECKING THE SEAT BELT X
7.4.1.8 CHECKING THE LEAKING OF
X
OIL
7.4.1.9 CHECKING THE QUICK
X
COUPLER
7.4.1.10 CHECKING THE WATER
X
AND SEDIMENTS SEPARATOR
7.4.2.1 CHECKING THE COOLER

X
PIPES
7.4.2.2 CHECKING THE COOLANT
X
LEVEL
7.4.2.3 CHECKING THE TIRE
X
PRESSURE
7.4.2.4 CREASING THE PINS OF
X
BOOM AND CYLINDERS
7.4.2.5 CHECKING THE WHEEL
X
NUTS DRIVING TORQUE
7.4.3.1 CLEANING THE TERMINALS

X
OF THE BATTERY
79
7.4.3.2 CLEANING THE OIL TANK’S

X
BREATHER
7.4.3.3 CHECKING THE CYLINDER
X
RODS
7.4.3.4 GREASING ALL OF PINS X
7.4.4.1 CHECKING THE GEARING

X
CHAIN TENSION
7.4.4.2 ADJUST THE CHAIN IF
X
NECESSARY
7.4.4.3 CHECKING THE FAN BELT X
7.4.4.4 CLEANING THE RADIATOR X
7.4.4.5 CHECKING THE OIL LEVEL
X
IN THE GEAR CHAIN BOX
7.4.4.6 CHANGING THE ENGINE OIL X
7.4.4.7 CHANGING THE ENGINE OIL
X
FILTER
7.4.4.8 CHANGING THE FUEL
X
FILTER
7.4.4.9 CHECKING THE NUT
TORGUE OF THE HYDRAULIC
X
MOTOR AND THE HUB HOLDING
TO THE CHASSIS
7.4.5.1 CLEAN THE FUEL-WATER

X
SEPATATOR
7.4.5.2 CLEAN THE TIGHTENESS OF
X
PUMP FIXING SCREWS
7.4.5.3 CHECKING THE BATTERY
X
FLUID LEVEL
7.4.5.4 CHANGING THE
X
HYDRAULIC OIL FILTER
7.4.6.1 CHANGING THE OIL IN THE

X
GEAR CHAIN BOX
HYDRAULIC OIL AND CLEAN THE X
SUCTION
7.4.6.3 CHANGING THE AIR FILTER X
7.4.6.4 CHECKING THE PRESSURE
X
OF PUMP AND VALVE
80

X
HYDRAULIC OIL TANK BREATHER
7.4.6.6 CHECKING THE TIGHTNESS
X
OF CYLINDER HEAD SCREW
7.4.6.7 CHECKING THE LOOSENESS
X
OF VALVE
7.4.7.1 CHANGING THE COOLANT X

7.4.7.2 CHANGING THE SUCTION
X
FILTER
7.4.7.3 CHECKING THE STARTER
X
AND ALTERNATOR
7.4.8.1 DRAINING THE FUEL TANK X
BS: Before Starting

WR: When Required
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7.4.1 BEFORE STARTING

7.4.1.1 CHECKING ENGINE OIL LEVEL
• Cool down the oil if the engine was running before. In this case wait 15 minutes for
cooling down the oil before carry out the check.
• For checking the oil level, raise the dipstick (see photo below) and read the oil marks on
it. The oil sign should be between the Min. and
Max. limit written on the dipstick.
• If the oil mark is lower than the minimum limit,
refill engine oil as soon as possible. Refill the
engine oil through the inlet shown in the right
figure.
7.4.1.2 CHECKING ENGINE COOLANT LEVEL
• Cool down the coolant if the engine was running
before. In this case wait 15 minutes for cooling
down the coolant before carry out the check.
• The coolant level in the coolant tank should be
between the two limit marks.
• If necessary, add coolant through the coolant cap
(shown in the right figure).
• Do not remove the coolant cap when the fluid is
hot, since it could spray out violently and cause
injury.
7.4.1.3 CHECKING ENGINE FUEL LEVEL
• For checking the engine fuel level use the
indicator located in the instrument panel. The
indicator should comes on when turning the
ignition key to position “ON”.
• If the fuel level is low, refuel before starting
engine.
7.4.1.4 CHECKING THE HYDRAULIC OIL LEVEL
• Check the oil level through the gauge located in
the backside of the hydraulic tank. The oil level
has to be between the two limit marks on the
gauge. Refill with the suitable oil if necessary.
• When refill hydraulic oil, do not exceed the Maximum limit.
• The level must be checked with the machine in a level surface and the oil cooled down.
• Check the hydraulic circuit when an abnormal decrease of the oil level is observed.
• Before check the level in the gauge, release the pressure inside the hydraulic tank by
loosing the filling cap.
• Before check the level in the gauge, release the pressure inside the circuit by lowering
slowly the hydraulic cylinders.
7.4.1.5 CHECKING THE ELECTRIC CABLES
• Make sure all relays and fuses are well fastened and there are not loosen cables or
connections.
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• Make sure there is no sign of short circuit in the electrical system.

• Make sure there is no corroded cable or fuses. Change all the corroded cables or
fuses with same character.
7.4.1.6 CHECKING THE TIRES
• Over inflated or overheated tires could burst during operation of the machine.
• Check visually the state of the tires. Make sure there are not cracked and make
sure there are not wore out points.
• Check manually that all the nuts are tightened well.
7.4.1.7 CHECKING THE SAFETY BELT
• Check visually the screw and nuts that fasten the security belt. Make sure they are
in good condition.
7.4.1.8 CHECKING THE LEAKING OF OIL
• Check visually the hydraulic oil circuit and make sure there are no leaking in it. If any
leaks appear, repair it immediately.
• Clean the spilled oil if there is.
7.4.1.9 CHECKING THE QUICK COUPLER
• Check visually that the two coupler-pins are engaged. If any of the mechanisms is
loosen (this means one or two pins are not engaged), you and the people around
could result injured or even death.
• Never stand under the bucket, when the boom is raised.
7.4.1.10 ECKING THE WATER AND SEDIMENTS
SEPARATOR
• The fuel filter has a separator for water and
sediment that it is recommendable to drain every
time you start the engine.
• The water and sediment separator is located in the
engine compartment. See the picture.
• When the ring floats on the water present in the
separator, it needs draining. Do the following
procedures:
1) Close the handle to cut the flow of fuel
to the separator.
2) Loose the wring in the bottom side of the separator. Drain the water until
clear fuel flows out and close the wring.
3) Open the handle to let the fuel flow into the separator.
4) Drain the fuel tank .
5) Bleed the fuel supply circuit .
7.4.2 EVERY 50 HOURS OF OPERATION
7.4.2.1 CHECKING THE COOLER PIPES
• Check the entire cooler pipes for any leakage. The machine could overheat if a big
quantity of coolant spells out. The hydraulic circuit could result damage if a big
quantity of oil spells out.
83
• The operator has to conscious of he importance of the coolant system and also of
the hydraulic circuit.
7.4.2.2 CHECKING THE COOLANT LEVEL
• Cool down the engine in case it was running before. In this case wait 15 minutes for
cooling down the engine before carry out the check.
• Carry out the check with the machine on an level surface.
• Loosen the radiator cap slowly in order to release the pressure inside the radiator.
• Add coolant to the radiator if necessary.
• Do not remove the radiator cap when the fluid is hot, since it could spray out
violently and cause injury.
• Make sure there is not air leakage in the radiator-expansion tank tube. It could
mark the wrong coolant level.
7.4.2.3 CHECKING THE TIRE PRESSURE
• Never exceed the pressure recommended in this manual. The tire could blast, you
or the people around could result injured or even death .
• While inflating the tires never stand beside to the tires.
• While inflating the tires make sure you use the proper equipment.
• In case a tire has lost the entire air, only specialized person can repair it.
7.4.2.4 GREASING THE PINS OF BOOM AND CYLINDERS
• Grease the pin located in the top of the boom. (See drawing 5.3.5 Lubrication point)
• Grease the pins that connect the cylinders (See drawing 5.3.5 Lubrication point)
7.4.2.5 CHECKING THE WHEEL NUT DRIVING TORQUE
• Check the wheel nut torque every 50 hours. Refer to the following table.
Driving Torque for Wheels
Front Wheels Rear Wheels
150 Nm 150 Nm

7.4.3.1 CLEANING THE TERMINALS OF THE BATTERY
• Keep the battery terminals clean is very important, since it ensure a good electricity
flow.。
• Clean the battery with gloves. Never clean the terminals directly with your hands.
7.4.3.2 CLEANING THE OIL TANK’S BREATHER
• Keep the tank breather clean is very important, since it ensures a pressure release inside
the oil tank.
7.4.3.3 CHECKING THE CYLINDER RODS
• Make sure the cylinder rods are not corroded or damaged. It could reduce the machine’s
efficiency.
84
7.4.3.4 GREASING ALL OF PINS

• Grease the pins specified in the item 5. 8 Lubrication Points.
7.4.4 VERY 250 HOURS OF OPERATION
7.4.4.1 CHECKING THE GEARING CHAIN TENSION
• Every transmission side is compound with 2 chains. One chain for one wheel.
For checking the rear gearing chain tension proceed as follow:
1) Block the machine by pressing the Parking brake button.
2) Lift up the rear part of the machine and maintain it lifted by putting blocks
under the machine (See picture below).
3) Fix a point on the perimeter of the tire. Try to do it in the highest position.
4) Try to move the entire wheel.
5) If the angle between the original position of the point and the turned position
is more than 2 degree, the gearing chain is loosening.
Proceed on the same way for checking the other rear gearing chain.
Proceed on the same way for checking the front chain.
7.4.4.2 ADJUSTING THE CHAIN IF NECESSARY
Proceed as follow to tense the gear chain:
1) Remove the wheel.
2) Adjust the adjusting screw against the
hub-holding plate (See picture below).
3) Loosen the screws that support the
hub-holding plate (See picture right).
4) Turn the adjusting screw a few millimeters for tensing the chain.
5) Fasten the screws that hold the hub holding. Try to fasten the screws every 3
screws step by step.
6) Mount the wheel.
• Try to do the adjustment on an level and clean surface. Make sure it is not slippery.
7.4.4.3 CHECKING THE FAN BELT
• Check the engine manual
7.4.4.4 CLEANING THE RADIATOR
• Use jet of compressed air or low-pressure water for cleaning the radiator.
• If necessary use products available in the market
specially prepared for cleaning radiators.
• Never use oily products, since it facilitate the
adhesion of dust and reduces the efficiency of
the radiator.
7.4.4.5 CHECKING THE OIL LEVEL IN THE
GEAR CHAIN
• The checking has to be carried out in an level
surface.
85
Proceed as follow to check the gear chain oil level:

1) Screw off the screw located in the bottom side on the chassis (See picture
below).
2) If the oil reaches the high of the hole, there is enough oil. If the oil is lower
than the hole, refill with the recommended type oil given in this manual.
7.4.4.6 CHANGING THE ENGINE OIL
• Proceed as follow to change the engine oil: refer to the ENGINE OPERATION AND
MAINTENANCE MANUAL before you doing change the engine oil.
1) Put a suitable container under the machine so that the oil can be drained
into it.
2) Remove the draining oil screw so that the oil flows into the container.
3) During the oil is flowing remove the engine refilling cap, in order easy
the flow.
4) Check and clean the engine oil drain plug treads and sealing surface,
install the drain plug.
5) Refill with the recommended engine oil given in this manual.
6) Fill the engine oil till the oil level to the H mark on the dipstick.
7) Close the refilling cap.
• Do not proceed to change the engine just after stopping the engine, since the oil is
still hot. Wait a while until the oil cool down.
• Oil is considered special waste. It has to be collected following the current
environment regulation.
7.4.4.7 CHANGING THE ENGINE OIL FILTER
Proceed as follow to change the engine oil filters:
1) Unscrew the filter head with a suitable tool.
2) Clean the filter support.
3) Lubricate the seal of the new filter.
4) Screw the filter. Turn it by hands for a half turn.
5) Refill the engine with new oil. It has to be the oil recommended in this
manual.
6) Start the engine and make sure the indicator for the engine oil pressure goes
out.
• Make sure you use the filter recommended in this manual.
• Do not proceed to change the engine oil filter just after stopping the engine, since
the oil is still hot. Wait for a while until the oil cool down.
• Oil filters are considered special waste. It has to be collected following the current
• Use special spanner in order to ensure not damage the filter.
7.4.4.8 CHANGING THE FUEL FILTER
• Take into consideration that the fuel is flammable. Take care by handling with fuel.
• Use always the fuel filters recommended in this manual.
86
Proceed as follow for changing the fuel filter located in the engine compartment (See picture
below):
1) Remove the fuel filter.

2) Clean the gasket surface of filter head with a lint-free cloth.
3) Discard the O-ring.
4) Install a new O-ring.
5) Fill the new filter with clean fuel, and lubricate the O-ring seal with clean
lubricating engine oil.
6) Install the new filter.
• Make sure you use the filter recommended in this manual.
• Do not proceed changing the fuel filter just after stopping the engine, since the
engine body is still hot.
• Oil filters are considered special waste. It has to be collected following the current
• Use proper tools only in order to avoid damaging the filter.
7.4.4.9 CHECKING THE NUT TORQUE OF THE HYDARULIC MOTOR AND THE
HUB HOLDING TO THE CHASSIS
• For the operator’s security check the screw that hold the hydraulic motor to the chassis.
Take as reference the following driving torque given in the following table:
Driving Torque for Hydraulic Motor 160 Nm
• Check the driving torque that holds the hub-holding.

Take as reference the following driving torque given in the following table:
Driving Torque for Hub-Holding 160 Nm
87

7.4.5.1 CLAEN THE FUEL-WATER SEPARATOR
Proceed as follow for cleaning the fuel-water separator:：
1) Turn the handle to cut off the fuel flow into the separator.
2) Loosen the fuel-water separator by a ring (See picture below).
3) Clean the inner part of the separator with fuel.

4) Mount again the separator by tightening the ring again.
5) Release the handle to allow fuel into the separator.
6) Bleed the fuel circuit by turning a while ignition key to position START
during 20 seconds.
• Before precede to clean the separator cool down the engine.
• After bleeding the circuit, turn the ignition key to preheating position for 2 minutes
and then start the engine.
• Take into consideration that fuel is a flammable fluid. Clean the spilled fuel in
order to prevent risk of fire.
7.4.5.2 CHECK THE TIGHTENESS OF PUMP FIXING SCREWS
• Check and if necessary tighten the screws of the gear pump fixing point.
• Take as reference the driving torque shown in the following tables:
Driving Torque for Piston Pump Elastic Driving Torque for Gear Pump Piston
Coupler Pump
130 Nm 130 Nm
7.4.5.3 CHECKING THE FLUID LEVEL OF THE BATTERY

For checking the fluid level of the battery proceed as follow:
88
1) Open the plug on the topside of the battery.

2) Check the acid level. The acid level has to be 6 mm above the plate edge.
3) Refill with distilled water if necessary.
3) Put back and tighten the plug.
• Follow all the security regulation describes in the section 2.5.6.
• Park the machine on an level surface before checking the fluid level.
• In case you get in contact with the electrolyte, wash with plenty water and consult a
doctor.
• Grease the terminals with special anti-oxidation if they are oxidized.
7.4.5.4 CHANGING THE HYDRAULIC OIL FILTER
• Never change the hydraulic oil filter when the oil is warm.
• Used filters must be collected following the local regulation.
Proceed as follow for changing the hydraulic oil filter:
1) Remove the oil tank cap for releasing the remaining pressure inside the tank.
2) Remove the oil filter.
3) Renew the gasket when putting the
new filter.
4) Put back the oil tank cap.
7.4.6.1 CHANGING THE OIL IN THE GEAR
CHAIN BOX
Proceed as follow for draining the oil from the gear chain
box:
1) During the oil is hot (just after use the machine) screw off the drain plug
located in the front part of the chassis (see picture below).
2) While the oil’s draining screw off the screw located on the top of the
chassis (see picture below).
3) Once the oil is drained screw on the plug located in the front part and fill
through the plug located in the top until the oil reaches the lower edge of
the hole. Only fill with oil recommended in the manual.
4) Tighten the screw located in the side.
7.4.6.2 CHANGING THE HYDARULIC OIL AND
CLEAN THE SUCTION
Proceed as follow to change the hydraulic oil:
1) Park the machine on a level surface
and release the residual pressure by
moving a few times all the cylinders.
Lower the boom and rest the bucket on
the floor.
2) Cool down the oil by waiting a few
minutes.
3) Remove the filling cap from the hydraulic tank.
89
4) Position a suitable container under the machine, so that the oil can flow into it.
5) Turn on the cock located under the hydraulic tank (See picture below).
6) Fill the circuit again with recommended hydraulic oil given in this manual.
7) Make sure hydraulic oil reaches the desiderate level. After the oil level has
reached his level, the hole is completely full of oil when removing the plug in
the piston pump.
8) Also check the oil level on the gauge located in the backside (See picture
below).
9) If the gauge does not mark the maximum level and in the pump the hole is
completely full, top up with oil recommended in this manual.
10) Wait a few minutes before operate the machine.
11) Move slowly every hydraulic cylinder.
12) Check again the gauge and in case it needs, refill it with more oil.
• Never start the engine with empty oil tank, since it could damage hydraulic
components.
• Hydraulic oil is considered as danger for the environment, since it can damage it.
Throw the oil following the local regulations.
7.4.6.3 CHANGING THE AIR FILTER
• Always when the indicator of air filter pressure in the panel comes on, change the
filter.
• Never wash the air filter, always change it with a new one.
• Never run the engine without air filter.
Proceed as follow to change the air filter:
1) Stop the engine and wait till it cools
down.
2) Loose the three flanges (1) that close
the filter. Remove the cap (2).
3) Remove the filter (3) inside from
inside. If necessary remove the part
inside the filter (4).
90
4) Clean inside the filter-container.

5) Introduce the new filters carefully inside the filter-container.
6) Tighten the flanges and close the filter-container. Make sure the air’s
entrance (5) is in the bottom side of the air filter.
7) Make sure the switch (6) is connected.
7.4.6.4 CHECKING THE PUMP’S PRESSURE AND THE VALVE
7.4.6.5 CHANGING THE HYDRAULIC OIL TANK BREATHER
7.4.6.6 CHECKING THE TIGHTNESS OF THE CYLINDER HEAD SCREW
7.4.6.7 CHECKING THE LOOSENESS OF THE VALVE
91

7.4.7.1 CHANGING THE COOLANT
• Never change the coolant just after stopping the engine, since the coolant is still
warm. Let the coolant cool down until it goes under 40-45˚C.
• Never loosen the coolant cap when the coolant is still hot. Warm water could spill
out violently and produce burnings.
• Always loose the coolant cap slowly, in order to release the pressure inside the
coolant tank.
Proceed as follow for changing the coolant:
1) Loosen slowly the coolant tank cap.
2) Open the drain plug located in the bottom side of the radiator (See picture
below).
3) Remove the drain plug located in the bottom side of the engine.
4) Drain the coolant until it stops to flow.
5) Put on and screw up the two drain plug again.
6) Refill with the recommended coolant described in this manual.
7) Start the engine and let it run at idle speed for a while.
8) Stop the engine.
9) Check the coolant level. If necessary refill until the level reaches the right
level.
7.4.7.2 CHECKING THE STARTER AND ALTERNATOR
7.4.8 WHEN REQUIRED
7.4.8.1 DRAINING THE FUEL TANK
• Drain the fuel tank always with temperature exceeding 0˚C and before starting the
machine. If the temperature is lower than 0˚C drain the fuel tank after using the
machine, to prevent the condensate.
Proceed as follow for draining the fuel tank:
1) Remove the fuel tank cap.
2) Position a container under the draining valve located in the bottom side of
the chassis.
3) Release the draining valve.
4) Led the fuel flow totally.
5) Close the draining valve.
6) Refill the tank with the fuel type recommended in this manual.
92
7.4.9 TROUBLE SHOOTING

Trouble Cause Solution
Electric system
Lamps do not work properly • Fault cables • Check and repair any
even with engine running at loose terminal and
high speed connection
Lamps come on • Faulty fan belt tension • Check the belt tension
intermittently with engine and adjust it or change it if it
running is necessary
Charge warming light dose • Faulty alternator • Change
not go out when the engine
running, even at high speed • Faulty cables • Check and repair
Alternator emits abnormal • Faulty alternator • Change

noise
• Faulty cables • Check and repair
Starter does not work with • Battery charge • Charge battery
key in START position insufficient
• Faulty main fuse • Change
Starter pinion engages and • Battery charge • Charge battery
disengages while starting insufficient
engine
Engine oil pressure warming • Faulty bulb • Change
light does not come on when
engine is stopped • Faulty pressure sensor • Change
Charging warming light • Faulty bulb • Change

dose not come on when
engine is stopped • Faulty cables • Check and repair
Hydraulic system
• No oil in the tank • Refill oil
• Faulty pump • Check, then repair or
change
Pumps emit abnormal noise
• Hydraulic oil • Change the oil
unsuitable for the
temperature
• Faulty pump • Check, then repair or
change
Equipment moves only at • Max. pressure valve • Reset or change
low speed setting incorrect, or valves
closed due to impurities
• Dirty drain filter • Change
93
Power system
• Oil level too low • Refill
Oil pressure warming light
• Oil filter clogged • Change filter
remains on even with engine
at high speed • Oil unsuitable for the • Change
ambient environment
• Coolant fluid level • Refill
low
• Radiator leakage • Repair
• Fan belt slacked • Check belt tension and
adjust
Steam comes out of radiator
breather. • Mud or limestone • Change coolant and
accumulated in cooling clean cooling system
system
The engine coolant • Radiator fins damaged • Repair or clean
temperature indicator or closed
reaches overheating range
• Faulty thermostat • Change
• Radiator cap loosen or • Tighten cap or change
broken unit
• Working at too high
altitude
Coolant temperature • Faulty instrument • Change
indicator always at the end
of right scale
Coolant temperature • Faulty thermostat • Change
indicator always at the end
of left scale • Faulty instrument • Change
• No fuel • Refuel
Engine dose not start with
• Air in fuel system • Bleed system
starter running
• Compression defect • Adjust valve clearance
Exhaust gases white or light • Too much oil in oil • Drain some oil
blue pan
• Unsuitable fuel • Change with correct
fuel
• Air cleaner clogged • Clean or change
Exhaust gases occasionally
• Faulty injectors • Change
tend to be black
• Faulty compression • Adjust valve clearance
Combustion noise • Faulty injectors • Change
occasionally resembles a
blow
94

• Fuel with low cetane • Change with correct
rating fuel
Abnormal noises (during • Overheating •

combustion or in mechanical • Exhaust silencer • Change
parts) inside damaged
• Excessive valve • Adjust valve clearance
clearance
Transmission system
• Oil level insufficient • Refill
• Suction filter clogged • Change
• Faulty flexible coupler • Change coupler
Machine moves neither • Max. pressure valves • Clean or change valves
forward nor reverse faulty or dirty
• Positioning hydraulic • Restore connection
connection interrupted
• Travel motor faulty • Repair or change
• Oil level too low • Refill
• Presence of foam • Use the recommended
oil
Machine moves with delay
• Suction pipe tightness • Check and eliminate
(with abnormal noise)
leakage
• Endothermic engine • Change diesel oil filter
does not reach max. speed and check injection pump
• Auxiliary fuel pump • Repair or change
(gear pump) faulty
• Max. pressure valve • Reset
setting incorrect
Traction force in the two
• Connection to servo • Restore connection or
travel directions is
control faulty or lever angle shift lever to correct position
insufficient
incorrect
• Pressure relief valve • Reset
setting incorrect
• Excessive oil • Check oil lever and
temperature clean exchanger
Traction force is insufficient • Endothermic engine • Reduce loads due to
in only one direction strongly overloaded lifting
95

• Incorrect setting of the • Set valve
max. pressure valve
relevant to that direction
• Oil level too low • Refill oil
• Exchanger clogged or • Check and change if
dirty necessary
• Unsuitable oil • Change with correct oil
• Suction pipe tightness • Check and eliminate
leakage
Oil overheating
• Setting and operation • Check setting, repair or
of the max. pressure valves change
• Travel pump faulty • Repair or change
• Pressure relief valve • Set valve
with high setting
• Endothermic engine • Change diesel oil filter
dose not reach max. speed and check injection pump
• Auxiliary pump (gear • Check, repair or change
Machine dose not reach
pump) faulty
max. speed
• Pilot pressure • Set
insufficient
• Pressure relief valve • Set to rated value
setting incorrect
• Mechanical • Check if rotation is
Machine decelerates
connection with servo smooth
discontinuously
control lever too hard
• Engine power drop • Check clogging of fuel
filter, injection pump and
Machine accelerate slowly valves
• Pressure relief valve • Set to rated value
setting incorrect
• Sealing rings faulty • Change
• Counter pressure in • Drain pipes clogged or
Oil leakage from engine
pump casing damaged
propeller shaft and/or pump
• By-pass valve setting • Check and restore
too high
Others
Fuel completely depleted • Fuel runs out of • Refuel and bleed the
system before start the engine
96

again
• Alternator faulty • Repair or change
Battery completely depleted • Consume electric • Charge the battery

power when the engine is
• Or start the engine with
stopped
booster cables
• Can not get out by • Use a wire rope suitable
Machine gets stuck in mud itself to remove the machine
through the tow hook
8 INFORMATION OF MANUFACTURER
Company Name: Hunan Sunward Intelligent Machinery Co., Ltd.
Brand:
Address: No.16, Lixiang Road (M), Xingsha, Changsha, 410100 Hunan, China
Tel: 0086 731 4020688 4020666
Service point:
Information of Distributors
Information of Distributor
Name:
Address:
Tel:
Fax:
Email:
Contact:
Remark
97

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4.3.1 OUTSIDE VIEW OF GEAR PUMP .......................................................................................... 36

7.4.4 VERY 250 HOURS OF OPERATION ............................................................................................ 85

ITEM UNIT SYMBOL

Temperature Celsius degree °C

1.5 DEFINITION OF “LEFT” SIDE AND “RIGHT” SIDE

1.6 PRECONDITION TO USE THE MACHINE

If not avoided, it has great possibility to lead to serious

If not avoided, this situation could cause serious injuries

If not avoided, this situation may cause minor or moderate

It is used for precautions that must be taken to avoid actions

It is used for information that is extremely useful to know.

Moving crawlers, when Entanglements in can

See manual book

Safety pin for boom

2.1.2 ACOUSTIC SIGNS

The max noisy level out of cabin.

The max noisy level in cabin.

2.2 LOCATION OF THE SAFETY LABELS

2.3.2 CLOTHING AND PERSONAL PROTECTION

z Inappropriate clothing may lead to injury to the

1) Park the machine in a safe position.

2.3.5 PREVENTION OF BURNS

Voltage of Cables (kV) 1.0 6.6 33 66 154 275

2.4.2 RUNNING THE ENGINE DURING THE MAINTENANCE

z If it is necessary to carry out service and

2.4.4 SAFETY RULES FOR HIGH-PRESSURE OIL AND HOSE

2.4.5 PREVENTION ON THE STARTER AND

3 GENERAL DESCRIPTION OF THE MACHINE

3.1.2 REAR VIEW

3.1.3 MACHINE DISTRIBUTION

1. Bucket 2.Working lamp

Item Specification SWL3210

POWER OUTPUT 54.9Kw

3.2.4 ELECTRIC SYSTEM

System voltage 12V

Hydraulic Oil TOTAL AZOLLA ZS46,

Engine oil 13.2

Travelling Mechanism 2X15

3.2.8 TORQUE FOR SCREWS

3.2.9 LUBRICATION POINTS

Front pump X2 X1 Y X1 X2 Rear pump

Relief valve of Relief valve of

Relief valve of Relief valve of

Test port MB of Port G Test port MB of Port T

Test port MA Test port MA of

Bolt of max Bolt of max

4.1.2 PIPELINE CONNECTION (FOR TESTING) OF MAIN TRAVEL PUMP

4.1.3 SET PRESSURE DATA FOR MAIN TRAVEL PUMP

4.2 TRAVEL MOTOR

Pilot oil supply Pilot oil supply port

4.2.2 PICTURE OF BRAKE OIL PIPES’ CONNECTION

4.2.3 ROTATION DIRECTION OF TRAVEL MOTOR.

4.3 WORKING REAR PUMP

Gear pump 1 Suction port Gear pump 2

4.3.2 BREAKDOWN DRAWING OF GEAR PUMP

4.3.5 SET THE DATA

4.4 BUCKET-LIFT VALVE

POS. COD. PART NAME 名称 QTY REMARK

POS. COD. PART NAME 名称 QTY REMARK

POS. COD. PART NAME 名称 QTY REMARK