SUNWARD SWTL 4518 Operation & Maintenance Manual

SUNWARD SWTL 4518 Operation & Maintenance Manual

Skid-steer loader

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Operation & Maintenance Manual
SKID-STEER LOADER
This manual should be always kept on the machine
HUNAN SUNWARD INTELLIGENT MACHINERY CO., LTD.

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Summary of Contents for SUNWARD SWTL 4518

  • Page 1 Operation & Maintenance Manual SKID-STEER LOADER This manual should be always kept on the machine HUNAN SUNWARD INTELLIGENT MACHINERY CO., LTD.
  • Page 2: Table Of Contents

    SWTL4518 Operation & Maintenance Manual INDEX GENERAL SAFETY RULES AND OTHER SAFETY INSTRUCTION..........4 GENERAL SAFETY RULES......................4 OTHER SAFETY INSTRUCTION ..................... 4 1.2.1 GENERAL SIGNS ..........................4 1.2.2 GENERAL PROTECTION......................8 1.2.3 PREVENTIONS DURING OPERATING ..................11 1.2.4 MAINTENANCE PREVENTION ....................14 TRANSPORTATION AND STORAGE OF THE MACHINE ..............
  • Page 3 SWTL4518 Operation & Maintenance Manual 5.13 USE OF THE QUICK COUPLER ..................... 49 5.13.1 ASSEMBLE THE BUCKET ......................50 5.13.2 DISASSEMBLE THE BUCKET ....................50 5.13.3 AJUST THE QUICK COUPLER MECHANISM ................50 5.14 USE OF AUXILIARY PEDAL......................51 5.15 HIGH FLOW SYSTEM......................... 52 5.16 MAXIMUM IMMERSION IN A FLUID .....................
  • Page 4 SWTL4518 Operation & Maintenance Manual 6.5.6.2 CHECKING THE PUMP’S PRESSURE AND THE VALVE ..........69 6.5.6.3 CHANGING THE HYDRAULIC OIL TANK BREATHER............ 69 6.5.6.4 CHECKING THE TIGHTNESS OF THE CYLINDER HEAD SCREW ......... 69 6.5.6.5 CHECKING THE LOOSENESS OF THE VALVE ..............69 6.5.7 EVERY 2000 HOURS OF OPERATION.....................
  • Page 5: General Safety Rules And Other Safety Instruction

    • 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.
  • Page 6 SWTL4518 Operation & Maintenance Manual GENERAL LABELS moving parts, when Entanglements in can cause serious injury High temperature See manual book Note...
  • Page 7 SWTL4518 Operation & Maintenance Manual Prevent electric shock Prevent slip Oil level Fuel Engine oil filter core Fuel oil filter core Air filter...
  • Page 8 SWTL4518 Operation & Maintenance Manual Engine water temperature Hydraulic oil level Hydraulic oil filter voltage Drag position Hoist position 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.
  • Page 9: General Protection

    SWTL4518 Operation & Maintenance Manual The max noisy level in cabin. 1.2.2 GENERAL PROTECTION (1) Clothes And Personal Protection • Inappropriate clothing may lead to injury to the operator. Please wear protective clothing while operating or performing maintenance such as hardhat, goggles glasses, mask gloves, safety shoes and headphones.
  • Page 10 SWTL4518 Operation & Maintenance Manual • Enter and leave the machine only when the machine is not moving unless it is in emergency. • Never hold on the joysticks. • Use always the appropriate handles while entering and leaving the machine. •...
  • Page 11 SWTL4518 Operation & Maintenance Manual 6) Stop the engine. (4) Prevent Fire from Fuel and Oil • Fuel and oil are easily to cause fire if they meet flame. • Keep always flame away from the fuel and oil. • Stop the engine and never smoke during refueling. •...
  • Page 12: Preventions During Operating

    SWTL4518 Operation & Maintenance Manual 1.2.3 PREVENTIONS DURING OPERATING (1) Safety Check Before Working 1) Check Working Site • Before any work, check the working site thoroughly. Make sure the working site ground conditions are available for the machine to work on. •...
  • Page 13 SWTL4518 Operation & Maintenance Manual 4) When connecting the cables, turn ignition keys of both the problem machine and normal machine to the position of OFF. 5) The correct connecting method is parallel (positive to positive and negative to negative). 6) Connect the positive (+) cable first when installing the booster cables.
  • Page 14 SWTL4518 Operation & Maintenance Manual (5) Moving On Unusual Surfaces • When moving on a slippery surface, keep low speed and avoid abrupt stops and turns. • When moving on loose ground, do not move the WRONG machine too close to the edge of cliffs and deep ditches.
  • Page 15: Maintenance Prevention

    SWTL4518 Operation & Maintenance Manual • 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. • Even going close to the high-voltage cables can cause electric shock. Always maintain a safe distance (see the table up) from the cables.
  • Page 16 SWTL4518 Operation & Maintenance Manual (2) Running The Engine During Maintenance 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.
  • Page 17 SWTL4518 Operation & Maintenance Manual (5) Prevention of Starter and Battery Before doing any check on the electric circuit, CONNECT disconnect the battery in order to cut off the current. If some electrical welding has to be done on the machine, it is necessary to disconnect the battery and also the alternator.
  • Page 18: Transportation And Storage Of The Machine

    SWTL4518 Operation & Maintenance Manual 2 TRANSPORTATION AND STORAGE OF THE MACHINE 2.1 LOADING OF THE MACHINE Always follow with the safety regulations when loading the machine on other vehicles. Any neglect on the regulations may cause serious accidents. Follow the following steps to load the machine to the transporting vehicles: 1) Park the transporting vehicle on a firm and level surface and apply the braking system.
  • Page 19: Lifting Of The Machine

    • Only use homologated eyebolts and sufficient cables. • Make sure the lifting equipment have enough capacity to lift the machine • Eyebolts are not supplied by Sunward normally. The owner of the machine is responsible for install the eyebolts on the cabin roof.
  • Page 20 SWTL4518 Operation & Maintenance Manual Replace filters (fuel oil filters of engine, oil filter of engine, oil filter hydraulic) Run the machine for a while to remove the left fuel oil after replacement of all liquid and filters. Remove and store the battery at place of suitable temperature and humidity. Charge the battery regularly.
  • Page 21: Assembly Insturction Of Machine

    SWTL4518 Operation & Maintenance Manual 3 ASSEMBLY INSTURCTION OF MACHINE 3.1 FIXING STEPS OF MACHINE Park the machine on stable and flat ground. Engage parking brake button to lock the machine Lower the working implement to ground or the lowest position. Put the bucket on ground Insert the wedge under the wheel to fix the machine.
  • Page 22 SWTL4518 Operation & Maintenance Manual • Besides of the standard equipments for SWTL series skid steer loader, Sunward also provides optional equipment. Please read the following information carefully before operation and refer to the involved instruction. • Only use the special or particular optional equipment recommended by Sunward or meeting with the request mentioned in the tables.
  • Page 23 SWTL4518 Operation & Maintenance Manual Max. Max. Size Max. Max. Work Max. Flow Weight Capacity Pressure Speed Equipment Width Height (cu m) (kg) (bar) (l/min) (mm) (mm) Bucket 2010 0.67 — — Multi function — — — — bucket Excavator Excavator ●3150 ▲2800...
  • Page 24 SWTL4518 Operation & Maintenance Manual 2500 Snow grader — Garbage — — — — collection Road sweeper — — — Fork 1600 ◆1300 — — Fertilizer fork 1650 — — — Grapple fork 1650 — ● Max. Extend Value ▲ Max. Dig Depth ★Value depend on diameter of Kelly bar ◆...
  • Page 25 SWTL4518 Operation & Maintenance Manual Quick coupling device should comply with standard of ISO8434-3. Any query about connection of hydraulic circuit, please consult with your local agent. 3.5.4 Connection of Standard Hydraulic Circuit Application of equipment which has hydraulic circuit with oil return to oil tank directly may also be available.
  • Page 26: Specification Of Machine

    SWTL4518 Operation & Maintenance Manual 4 SPECIFICATION OF MACHINE 4.1 DESCRIPTION OF MACHINE (1) Front View (2) Rear View...
  • Page 27 SWTL4518 Operation & Maintenance Manual (3) Top View (4) Machine Distribution 1. Bucket 2. Working lamp 3. Cabin 4. Exhaust pipe 5. Back door 6. Fuel oil tank 7. Engine hood 8. Hydraulic oil tank 9. Boom 10.Crawler...
  • Page 28: General Data

    SWTL4510 Operation Manual 4.2 GENERAL DATA ITEM SWTL 4518 4560kg Operating weight 1500kg Rated load 4500kg Tipping Load 0.67m3 Bucket volume 3000Kgf Breakout force (lifting cylinder) 2380Kgf Breakout force (tilting cylinder) 11Km/h Max traveling speed 4.2.1 OVERALL DIMENSION...
  • Page 29: Engine

    1530 ㎜ Width with excavating bucket 2010 ㎜ 4.2.2 ENGINE ITEM KUBOTA V3800DI 74Kw POWER OUTPUT 325N-m MAX TORQUE 2600rpm ROTATION 4.2.3 ELECTRIC SYSTEM ITEM SWTL 4518 80Ah or 100Ah Battery 12V-45A Alternator 12V-3.0A Starter motor System voltage Current total...
  • Page 30: Machine Identification

    SWTL4510 Operation Manual 4.3 MACHINE IDENTIFICATION There are several plates fixed to the machine for having a control of each machine SUNWARD produce. The plates have been fixed in different places of the machine. The following items describe all the plate.
  • Page 31: Security Devices

    SWTL4510 Operation Manual (4) Serial Number of Chassis The serial number of the chassis is placed as showed in the below picture. 4.4 SECURITY DEVICES 4.4.1 Restrain Bar • The restrain bar in made of steel and wrapped with a special rubber. At the end of the restrain bar there is a sensor.
  • Page 32 SWTL4510 Operation Manual 4.4.2 Boom Locks • Loader Locks are used for ensure that the boom not goes down when the machine is stopped and with the boom raised. It blocks the hydraulic cylinder so that it is impossible to close them when the cylinders are opened.
  • Page 33: Instruments

    SWTL4510 Operation Manual seat backward and forward till you find the best position for you, then release the adjusting handle. The locking pin will be engaged after release adjusting handle. Try to move the seat after your adjusting the seat’s position to make sure that the seat is locked well again.
  • Page 34: Joysticks

    SWTL4510 Operation Manual 4.6 JOYSTICKS Left joystick The left joystick is for controlling the movements of the machine. It is designed according to ISO 10968:1995. Its operating positions and relevant functions are showed in the following diagram. Direction Function Front Forward Back Backward...
  • Page 35: Switches And Buttons

    SWTL4510 Operation Manual Restrain bar A: The restrain bar is extremely important for the safety of operation. It will be a protection for the operator for avoid jump forward in case of sudden stop while traveling. B: It is also the safety device to lock the joysticks control.
  • Page 36 SWTL4510 Operation Manual Positions Marks Functions Left PREHEAT Neutral First right Second right START 2) Parking brake button When it pressed, the parking brake applies. The hydraulic flow to all the working equipments and traveling system is cut off. In this case the traveling system and working equipments are blocked and impossible to operate.
  • Page 37: Cabin

    SWTL4510 Operation Manual 9) Accumulator button: It is to cut off the battery supply circle. Switch off it when it is necessary. 10) Wiper Switch: This button positioned on the left control box is used to control the rain scraper. There is one button on the right joystick to control the spraying of water (optional with closed cabin) 11) Heater Switch This switch is located on the left control box and is used to control the heater.
  • Page 38: Auto-Levelling System

    SWTL4510 Operation Manual 4.9.1 Fasten The Seat Belt To fasten the seat belt, the operator needs to be seated and then follow these steps: 1. Take first the male clasp and introduce it into the female clasp until the blocking position. 2.
  • Page 39 SWTL4510 Operation Manual 4.13 Fuse Fuses are assembled in electric circuit to make sure max. limit current; a lot of fuses are in the electric box which is in the right back of cab(see following drawing)。 The following table is showing electricity system fuses: Color Rated Current (A) Related Circuit...
  • Page 40: Documents Case

    SWTL4510 Operation Manual 4.14 Relay Relay is located in the inner of fuse box。The following table is showing all relays and their position。 Position Description Location Flash apparatus Float control Travel brake valve control Brake indicating light Horn relay Brake light relay Safe relay Timing relay Hydraulic pilot relay...
  • Page 41: Battery

    SWTL4510 Operation Manual To open the rear cover you must open first the engine hood. There is a lever that allows you to open the rear cover (See the picture below). Lift up the lever and at the same time turns the door. Once you have disengaged the lock turn the door to the maximum and fix this position with the retainer.
  • Page 42: Operation Of The Machine

    SWTL4510 Operation Manual 5 OPERATION OF THE MACHINE 5.1 RUNNING-IN A new machine must be used carefully during the first 100 working hours. It is due to ensure the proper running-in of the components. Proper running-in is important to prolong the machine life working with excessive load during the first operation period can cause damages to the components.
  • Page 43: Normal Starting

    SWTL4510 Operation Manual • Do not keep the starter continuously rotating for more than 15 seconds. • It the engine does not start, wait for at least 2 minutes before trying again. • Never turn the key to positions of start and preheat when the engine is running.
  • Page 44: Stopping The Engine

    SWTL4510 Operation Manual • After the coolant temperature reaches 60°C, lower the restrain bar and slowly operate all working equipment cylinders for a while. • During warming up process, check if there is any abnormal noises or vibration s. If there is, settle the problem before working.
  • Page 45 SWTL4510 Operation Manual Movement MARK LEFT JOYSTICK POSITION Forward Backward Forward left 45° Forward right 45° Backwards left 45° Backward right 45° COUNTER ROTATING LEFT...
  • Page 46: Operation Of Working Equipments

    SWTL4510 Operation Manual COUNTER ROTATING RIGHT When you have to move on slopes, please operate the machine extremely according to the safety regulations. 5.7 OPERATION OF WORKING EQUIPMENTS For the auxiliary equipments operation, see the instruction of the auxiliary equipments. When the machine is equipment with the standard working equipments bucket, follow the operation as follow.
  • Page 47: Loading

    SWTL4510 Operation Manual 5.8 LOADING 5.8.1 LOADING ON LEVEL FLOOR 1) Start moving with the arm completely lowered and directs the bucket forward the base of the material what you want to load. 2) Move forward to the material, while the bucket is full, gradually raise the boom and fold the bucket until the end of stroke at the same time.
  • Page 48: Digging

    SWTL4510 Operation Manual 5.9 DIGGING Wrong digging operation will damage the machine. Carry out the follows steps and correct digging method while digging. 1) At the beginning of work, always adjust the bucket angle to the correct digging direction. 2) Once the bucket front edge reaches the depth, move forward and start filling. 3) To increase the efficiency, you have to adjust the position of bucket and boom combined while filling.
  • Page 49: Acceleration

    SWTL4510 Operation Manual 5) Apply the parking brake. 6) Stop the engine. 7) Remove the ignition key from the switch and leave the cabin. When it is ineluctably to park the machine on slopes, always park the machine with the bucket directed downwards.
  • Page 50 This quick coupler is suitable for many different types of working equipments homologated by Sunward. Some precautions for hitch and unhitch the working equipments: • To hitch or unhitch the bucket, choose a flat ground and make sure the machine is stable on the floor.
  • Page 51 SWTL4510 Operation Manual 5.14 ASSEMBLE THE BUCKET To engage the bucket or other equipments follow the steps below: 1) Rotate the levers to unlock the coupling pins completely. 2) Move the machine to align the quick coupler with the bucket. 3) Move machine slowly...
  • Page 52 SWTL4510 Operation Manual • Before adjust the mechanism make sure the bucket rest on the floor stably. • The quick coupler mechanism has to be adjusted periodically, so that it works correctly. • The mechanism is provided with a spring that regulates the force you need to turn the handle.
  • Page 53 (See picture below). • Never use auxiliary system that not approved by SUNWARD. • Always lock the safety retainer when not using the auxiliary pedal. • When connecting auxiliary equipment, make sure the pedal is in the neutral position and the safety retainer is engaged.
  • Page 54 SWTL4510 Operation Manual Only use cable strong enough to remove the machine. Release the parking brake before towing. Never tow the machine for long distance. When the machine is stuck in mud or out of order, we need other equipments to remove the machine.
  • Page 55 The machine has been designed and manufactured for giving the maximum autonomy with a minimum of maintenance. Before sell the machine SUNWARD has test the machine to ensure an optimum working of the machine. To keep the machine in good working it is recommended to do maintenance program describes in this manual.
  • Page 56 SWTL4510 Operation Manual • Avoid the skin contact with used oil since it could irritate it. If your eyes get in contact with oil clear your eyes with plenty water and if it persists contact a doctor. In case of ingest accidentally oil contact as soon as possible a doctor.
  • Page 57 SWTL4510 Operation Manual PART MANUFACTURER CODE Engine Air Filter FLEEGUARD 730402000049 Engine Oil Filter 730403000073 KUBOTA Engine Fuel oil Filter 730403000074 KUBOTA Hydraulic Oil Filter Internorman 730401000076 6.3.4 TORQUE FOR SCREWS Unless other specification, tighten the nuts and bolts according to the torques shown in the below table.
  • Page 58 SWTL4510 Operation Manual Maintenance and Lubrication Table Maintenance Period(hour) Item Oil Sign Maintenance No. 1000 2000 Fuel Oil Surface ■ Hydraulic Oil Surface ■ ● Work Device Pin Shaft ■ Engine Oil level ■ ● Coolant ■ ● Meter and Indicating light ▲...
  • Page 59 SWTL4510 Operation Manual • Coolant containing antifreeze is flammable. Never contact this type of coolant with a flame. • Use only coolant recommended in this manual. Never use any other coolant, since it could damage the rubber couplings. • Take special care in the engine fuel, since a wrong fuel damage the engine. •...
  • Page 60 SWTL4510 Operation Manual 6.5 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.
  • Page 61 SWTL4510 Operation Manual CHECKING THE FAN BELT CLEANING THE RADIATOR CHANGING THE ENGINE OIL CHANGING THE ENGINE OIL FILTER CHANGING THE FUEL FILTER CHECKING THE NUT TORGUE OF THE HYDRAULIC MOTOR AND DRIVE WHEEL CLEAN THE FUEL-WATER SEPATATOR CLEAN THE TIGHTENESS OF PUMP FIXING SCREWS CHECKING THE BATTERY FLUID LEVEL...
  • Page 62 SWTL4510 Operation Manual 6.5.1 BEFORE STARTING 6.5.1.1 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.
  • Page 63 SWTL4510 Operation Manual 6.5.1.5 CHECKING THE ELECTRIC CABLES • Make sure all relays and fuses are well fastened and there are not loosen cables or connections. • Make sure there is no sign of short circuit in the electrical system. •...
  • Page 64 SWTL4510 Operation Manual • 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. • The operator has to conscious of he importance of the coolant system and also of the hydraulic circuit.
  • Page 65 SWTL4510 Operation Manual 6.5.2.5CHECKING THE WHEEL NUT DRIVING TORQUE • Check the wheel nut torque every 50 hours. Refer to the following table. Driving Torque for Wheels Assembly Front Wheels Rear Wheels 150 Nm 150 Nm 6.5.3 EVERY 100 HOURS OF OPERATION 6.5.3.1 CLEANING THE TERMINALS OF THE BATTERY •...
  • Page 66 SWTL4510 Operation Manual 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.
  • Page 67 SWTL4510 Operation Manual 2) Clean the gasket surface of filter head by 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.
  • Page 68 SWTL4510 Operation Manual 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.
  • Page 69 SWTL4510 Operation Manual • 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. 6.5.5.4 CHANGING THE HYDRAULIC OIL FILTER •...
  • Page 70 SWTL4510 Operation Manual • 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. 6.5.6.2 CHECKING THE PUMP’S PRESSURE AND THE VALVE 6.5.6.3 CHANGING THE HYDRAULIC OIL TANK BREATHER 6.5.6.4 CHECKING THE TIGHTNESS OF THE CYLINDER HEAD SCREW...
  • Page 71 SWTL4510 Operation Manual 6.5.7.2 CHECKING THE STARTER AND ALTERNATOR 6.5.8 WHEN REQUIRED 6.5.8.1 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.
  • Page 72 SWTL4510 Operation Manual 6.5.9 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 high speed connection Lamps come • • Faulty fan belt tension Check the belt tension intermittently with engine and adjust it or change it if it...
  • Page 73 SWTL4510 Operation Manual Trouble Cause Solution 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 •...
  • Page 74 SWTL4510 Operation Manual Trouble Cause Solution • • Fuel with low cetane Change with correct rating fuel • • Overheating Abnormal noises (during combustion or in mechanical • • Exhaust silencer Change parts) inside damaged • • Excessive valve Adjust valve clearance clearance Transmission system •...
  • Page 75 SWTL4510 Operation Manual Trouble Cause Solution • • 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 •...
  • Page 76 SWTL4510 Operation Manual Trouble Cause Solution again • • Alternator faulty Repair or change • • Consume electric Charge the battery Battery completely depleted 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...
  • Page 77 SWTL4510 Operation Manual 8. OTHER DATA ENCLOSED 8.1 Electric Circuit Diagram SWTL4518 Electric Circuit Diagram 8.2 Hydraulic Drawing SWTL4518 Hydraulic Drawing...
  • Page 78 SWTL4510 Operation Manual 9. MANUFACTURER INFORMATION 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:...

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