Service Manual

SWE90N9

HUNAN SUNWARD INTELLIGENT MACHINERY CO., LTD.

 Foreword

This manual enables maintenance technician to be familiar with products by instructing

proper means to trouble-shooting and service. Make certain fully understand this manual and use
it during every service process for better result.
This manual includes technical information required in service. For easier reference and
understanding, this manual consists of below chapters with several sections contained.
1. safety precautions
This chapter provides safety guidelines during maintenance and service for personnel’s safe
operation.
2. chapter overview
This chapter provides dimensions, technical specifications, and working range information of
complete machine and master parts.
3. structural function and maintenance standard
This chapter illuminates structure and function of individual parts, and provides reference
about trouble shooting, maintenance and service.
4. test and failure diagnosis
This chapter provides instruction for inspection before or after service, and all adjustment
required in maintenance and service.
5. disassembly and assembly
This chapter provides all procedure that should be followed during disassembly and assembly,
and all safety precautions required in operation.
6. others
This chapter provides hydraulic system & electrical drawing, and air conditioning system
drawing (if equipped with air conditioning).

(Note: design and specification are subject to change without notice and obligation)

I
 Contents

1. Safety precaution.................................................................................................................... 1
1.1. Gerneral attention............................................................................................................. 1
1.2. Preparation ....................................................................................................................... 1
1.3. Attention in working hours .............................................................................................. 1
2. Summary ................................................................................................................................ 3
2.1. Dimensional drawing ....................................................................................................... 3
2.2. Technical specification ..................................................................................................... 5
2.3. Weight datas ..................................................................................................................... 6
2.4. Engine oil, fuel and coolant.............................................................................................. 7
3. Structure function and maintenance standard ...................................................................... 10
3.1. For mechanical device.................................................................................................... 10
3.2. For hydraulic equipments............................................................................................... 15
3.3. For electric equipments .................................................................................................. 32
4. Test and adjustment and Failure Diagnosis.......................................................................... 33
4.1. For mechanical structure device..................................................................................... 33
4.2. For hydraulic device....................................................................................................... 34
4.3. For electric equipments .................................................................................................. 44
5. Disassembly and assembly................................................................................................... 79
5.1. How to read this manual................................................................................................. 79
5.2. Radiator assy. Assembly and disassembly ..................................................................... 81
5.3. Hydraulic pump assembly and disassembly................................................................... 84
5.4. Slewing motor and slewing mechanism assembly and disassembly.............................. 88
5.5. Carrier roller installation and removal ........................................................................... 90
5.6. Slewing bearing assembly and disassembly................................................................... 91
5.7. Central swing joint assembly and disassembly .............................................................. 94
5.8. Hydraulic oil tank assembly and disassembly................................................................ 97
5.9. Multiple way valve assembly and disassembly............................................................ 100
5.10. Pilot control valve disassembly and assembly ............................................................. 103
5.11. Travel motor disassembly and assembly...................................................................... 106
6. Attachment drawings and others ........................................................................................ 108
6.1. Hydraulic system schematic diagram........................................................................... 108
6.2. Electric system schematic diagram .............................................................................. 109

II
1. Safety precaution
1.1. General attention
Improper operation is quite dangerous. Before repair and maintenance are carried out, it is
essential to read this manual carefully.
1. Before lubrication or repair is carried out, read all the safety notes on labels that are fixed on
the machine.
2. Before any operation, do wear safety shoes and hard hat. Do not wear loose work clothes or
clothes without buttons.
z Wear safety glasses when knocking some parts with a hammer.
z Wear safety glasses when polishing some parts with a grinding wheel.
3. If welding is needed, it should be carried out by trained skilled welder. During welding, wear
special gloves, apron, helmet, hard hat and work clothes that are suitable.
4. When an operation is carried out by two or more workers, the operating procedure should be
agreed upon before the operation. Before any operating procedure begins, you should inform
your partner workers of it. Hang a label reading “repairing” on the control table of control room
before any work.
5. All tools should be kept in good condition and operators are required to learn how to use
them.
6. Put the tools and disassembled parts in an appointed place in the repair shop. Do put the tools
and disassembled parts in a proper place. Keep the work area clean and make sure there are no
dirty things or oil stain on the floor. Smoke in the appointed area only. It is not allowed to smoke
during work hours.

1.2. Preparation
1. Before you fill oil or carry out any repair, put the machine on a level and hard ground,
underlay the wheels or tracks with pads to prevent the machine from moving.
2. Before operation, lower the push plate, ridger teeth, bucket and other working parts onto the
ground. If some working parts can not be lowered, apply the safety pin or pad to prevent them
from falling down.
3. When disassembly or assembly is needed, use pads, lifting jacks or racks to support the
machine before any operation.
4. Clean the steps by which you get on and off the machine and the pedals. When you get on or
off the machine, use handrails, steps or gang boards. Do not just jump in or off the machine. If
handrails, steps or gang boards are not available for use, racks should be used in sake of safety.

1.3. Attention in working hours

1. When disassembling the cover of oil filling opening, oil drain plug or hydraulic measurement
plug, release them gradually to prevent the oil from ejecting.
When disconnect or disassemble pipes for oil, water or gas supply, release the pressure in
pipeline first.

1
2. When the engine flames out and the water and oil in the pipeline are hot, be careful to avoid
being scalded.
3. Disconnect battery cable prior to operation. Make sure to disconnect negative terminal first.
4. When lifting heavy loads of parts, use winch or crane to check steel rope, chain and hook for
damage. Be certain to use over rated power crane. Assembling the crane at correct place.
Operating a winch or crane slowly to prevent lifting parts colliding with other objects and do not
work on the parts which are lifted by winch or crane.
5. When removing caps under internal pressure or spring pressure, maintain two bolts on the
other side. With pressure relieved, loosen bolts to remove.
6. Pay attention not to crash or damage cable during parts removal. Failure to do so can cause
electric spark.
7. During pipeline disassembly, prevent any leakage of fuel or oil from pipeline. In case of any
leakage on the floor, wipe it immediately, because fuel or oil on the floor can result in personnel
slip or fire.
8. Do not clean parts with gasoline in normal situation. However a small amount of gasoline is
allowed in an exceptional case.
9. Make sure to position all parts properly, and replace defective parts with new ones.
10. During hose or cable installation, do not let them make contact with other parts.
11. Make sure all high-pressure hose is free of distortion during hose installation. Damaged
pipeline is of highly dangerous. Therefore, pay undivided attention to it during high-pressure
hose installation. In addition, check connecting piece for proper installation.
12. Always operate with specified tightening torque during assembly or disassembly. When
assembling protective parts (e.g. protective guard) or installing other parts with sharp vibration
and high-speed rotation. Make sure they are properly installed.
13. When aligning two holes, do not insert fingers or hands into them so as to prevent finger
from being caught in.
14. Make sure all tools for measuring purpose are properly installed before attempting hydraulic
pressure measurement or other measuring procedures.
15. During track disassembly or assembly, please note that track may disengage out of place
abruptly; make sure the area on both end of the track is clear of persons.

2
2. Summary
2.1. Dimensional drawing
2.1.1 Drawing

2.1.2 Dimension parameters

Model
SWE90N9
Parameters
Outline dimension
mm 6400X2467X2723
(length×width×height)
A Wheel track mm 2335
B Track total length mm 2918
Platform to
C mm 798
ground distance
Platform Swing
D mm 1802
radius
E Chassis width mm 2320
Dimension F Track width mm 450
parameters Chassis to ground
G mm 348
distance
H Track height mm 658
I Total length mm 6403
J Cab height mm 2732
Upper carriage
K mm 2467
width
L Track gauge mm 1870

3
2.1.3 Working range figure

2.1.4 Working range parameters

Model
SWE90N9
Parameters
A Max. digging height mm 7273
B Max. dumping height mm 5146
C Max. digging depth mm 4202
Max. vertical digging
D mm 3680
depth
E Max. digging radius mm 6721
Worki
Max. parking level
ng F mm 6583
digging distance
range
Blade max. lifting
G mm 402
height
Blade max. digging
H mm 326
depth
R Min. swing radius mm 2049
Blade length×width mm 2320X415

4
2.2. Technical specification
Engine…………………………………………………………KUBOTA water cool diesel engine
Model…………………………………………………………………V3800-DI-T-E2B-SWD-S1
Discharge……………………………………………………………………………………3.769L
Cylinder number…………………………………………………………………………………4
Power…………………………………………………………………………61.6 kW /2200 rpm
Shaft coupling………………………………………………………… BOWEX 65-1O" FLE-PA
Radiator………………………………………………………………………… 4842.030.0000v1

Hydraulic device
Hydraulic pump………………………………………………………two variable axial plunger
pumps and one gear pump
Model……………………………………………………………………………………K3SP36C
Discharge……………………………………………………………………… 2x36+29+9mL/rev
Working pressure………………………………………………………… 30.5+30.5+26+3.9MPa
Multiple unit valve……………………………………………………KVMM-80 C0170-31219
Hydraulic pilot valve………………………………………………… All actions are operated by
two cross control lever to
control hydraulic ratio:
travel action is operated
by double acting pedals
or hand levers.
Model ………………………………………………………………left hand lever JRCVJ-07-LH
right hand lever JRCVJ-07-RH
duplex foot valve JRCVP-A-2-02
foot pilot valve JRCVP-B-1-06
push pilot valve JRCVD-02
Pilot system pressure………………………………………………………………………3.9MPa
Hydraulic cylinder(standard backhoe)…………………double acting compound sealed cylinder
Boom cylinder………………………………………………………………… φ85×φ55-925mm
Arm cylinder ………………………………………………………………… φ100×φ65-875 mm
Bucket cylinder………………………………………………………………… φ90×φ55-730mm
Earth-moving cylinder………………………………………………………… φ100×φ60-135mm
Swing hydraulic motor……………………………………… Plunger type fixed quantity motor
Model……………………………………………………………… MSG-44P-21 (B0250-44015)
Traveling hydraulic motor…………………………………………Plunger type two –stage
variable motor
Model…………………………………………………………………………………… GM10–A
Hydraulic oil tank……………………………………………………………………………135L
Hydraulic oil cooling device
Oil cooler……………………………………………………………………… 4842.030.0000v1
Fan driving…………………………………………………………………………Engine driving

5
Hydraulic oil filter
Oil return filter core model…………………………………………………………… SPF-248A

Swing machanism
Platform rotational speed…………………………………………………………………10 r/min
Swing bearing name……………………………………………… single row ball swing bearing
Swing braking………………………………………………………Hydraulic brake and spring
pressure multichip brake(NC)
Electric appliance
Accumulator………………………………………………………………………… 12V, 120Ah
Starting motor………………………………………………………………………… 12V,3.0 kW
Generator…………………………………………………………………………………12V,80 A
Fuel device
Fuel tank capacity…………………………………………………………………………… 145L
Traveling machanism
Traveling speed
High speed………………………………………………………………………………0~4.9km/h
Low speed…………………………………………………………………………………0~3km/h
Climbing capacity………………………………………………………………………………55°
Traveling braking …………………………………………………Hydraulic brake and spring
pressure multichip brake(NC)
Track tension……………………………………………………………………… Hydraulic type

2.3. Weight datas

NO. Parts name SWE90N9/weight(KG)

1 Machine 8630

2 Upper carriage assy. 3225

3 Under carriage assy. 3059

4 Boom 857

5 Arm 324

6 Bucket 252

7 Cab 281

8 Cover parts 193

9 Earth-moving device 439

6
2.4. Engine oil, fuel and coolant
Engine oil
NO Interval(hours)
Parts name Note
. 8 50 100 250 500 1000 2000
Check
1. Engine oil 1 △
oil level
7.4
2. Engine oil Replace △★ △
L
3. Engine oil filter Replace 1 △

Note: ★After initial 50 working hours, replace engine oil for excavator.
Maintenance must be operated according to diesel engine instruction.
·Performance class of engine oil varies seriously; generally API and CCMC standard should be
used.
·YANMAR Company recommends CE4/SG performance class SAE15W-40 heavy load engine
oil of (API).

Recommended engine oil name

brand
-20℃ to 0℃ -10℃to 35℃ 25℃to 40℃
Manufacturer
Esso Essolube D-3 10W 30 40

Apollo Apollo oil Super Wide 15W-40

Mobil 1310 Mobil Delvac1330 1340 ★

Fuchs 15W-40

Fina CF15W-40

Note: The excavator departed from factory has been filled with “★” marked engine oil.

7
 Fuel system
Interval (hours)
Parts name Qty.
8 50 100 200 400 1000 2000
1. Vent fuel tank sediment 1 △
2. Check and vent impurity in
1 △★ △
precipitator
3. Vent water and sediment in
1 △
water separator
4. Replace fuel filter 1 △
Leakage,
─ △
5. Check fuel crack, etc
hose Crack, bend,
─ △
etc

Note: ※1. Check and vent precipitator every 50 hours, replace every 1000 hours.
Recommended fuel:
Only use high quality diesel oil (GB252 normally No.0, No.10 in winter), don’t use kerosene.

Fill oil
Note: Dispose fuel carefully, it must stop engine before fill fuel. Never smoking when
you fill fuel into tank or fuel system works.

(1) Refer to “stop engine” chapter, park excavator and stop engine correctly.
(2) Check fuel display, and fill fuel if necessary.
(3) Prevent dirt, dust, water, and other sundries entering into fuel tank and fuel system.
(4) To prevent clogging, fill fuel after daily work, and not to splash fuel on excavator or ground.
(5) Fit on the cover after fill fuel.

Cooling system

Interval (hours)
Parts name Qty. 8 50 100 250 500 1000 2000
1. Check cooling water level 1 △
2. Check and adjust fan belt
1 ※1 △
tension
3. Replace cooling water 20L Twice in a year※2
4. Clean radiator △※
Outer 1
and hydraulic oil 3
cooler core Inner 1 When replace cooling water
5. Clean condensation
△※
device of air conditioner 1
3
(optional)
8
Note：
(1) Only maintain in the first inspection.
(2) When the machine is delivered, water and long lifetime cooling fluid have been filled in
the cooling system. You can replace the cooling water after a years or 2000 hours
operation if you always use manufacturer’s original long lifetime time cooling fluid.
(3) Operate the machine at dust area, shorten maintenance interval

(1) Cooling water

Fill soft and pure tap water or bottled water.
(2) Antifreeze
If the air temperature will be lower than 0℃ (32℉), it should add antifreeze and soft water to the
cooling system. In general, the ratio of antifreeze should be from 30% to 60%. If the ratio less
than 30%, the cooling system will be rusted; if more than 60%, the engine will be overheated.
Use 50% water and 50% glycol antifreeze, the engine can operate at the -37℃ perennially. Use
60% water and 40% glycol antifreeze, the engine can operate at the -20℃ perennially.
(3) Antirust
Add about 0.43L (0.4 Usqt) antirust in the new cooling water when you change cooling water, it
don’t need adding antirust when you adopt antifreeze.
(4) Replacement interval
Once a year or every 2000 working hours

9
3. Structure function and maintenance standard
3.1. For mechanical device
3.1.1 Engine parts

1. Muffler 2. Engine 3. Prefilter

4. Air filter 5. Shock pad 6. Engine mounting bracket
3.1.2 Cool system

1．Engine exhalent siphon

2．Radiator Technical specification：
3．Affix water tank Radiator: 4842.030.0000v1
4．Air director cover
5．Engine water inlet pipe

10
3.1.3 Swing bearing

1．Outer race of swing bearing 2．Steel ball 3．Inner race of swing bearing

3.1.4 Track frame and tension spring

1. Track 2. Guiding wheel 3. Guide plate

4. Tension device 5. Track roller 6. Carrier roller track frame
7. Track guiding machanism 8. Track frame
9. Driving wheel 10. Traveling motor
Track roller number (single side): 6 Carrier roller number (single side): 1

3.1.5 Guiding wheel

11
 Standard
Checking
NO. Standard Repayment measures
item
dimension limit
Flange outer
1 φ412 —
diameter
Track bearing
2 surface outer φ380 370
diameter Repair or
replace
Total width
3 110 —
u
Flange
4 53 —
width

3.1.6 Carrier roller

Checking item Standard

NO. Standard Repair Measures
dimension limit
Flange outer
1 φ120 —
diameter
Track bearing
2 surface outer φ92 82
diameter Repair or
Track bearing replace
3 32 —
surface width
4 Flange width 11 —
5 Total width 172.5 —

12
3.1.7 Thrust wheel

Standard

NO. Checking item Standard Measures

Repair
dimensio
limit
n
Flange outer
1 φ160 —
diameter
Track bearing
2 surface outer φ135 φ125
diameter
Installation
3 80 —
distance Repair or
4 Total width 146 — replace

Track bearing
5 116 —
surface width
6 Inner side width 50 —
Installation
7 210 —
distance

13
3.1.8 Track plate

Standard Measures
NO. Checking item
Standard dimension Repair limit
1 Height 18 10
Repair or
2 Thickness 27 —
replace
3 Point length 14 —

3.1.9 Working device

14
 1．Bucket
2．Connecting rod
3．Rocker arm
4．Bucket oil cylinder
5．Arm
6．Arm cylinder
7．Boom
8．Boom cylinder

Maintenance and lubrication position refers to operation manual.

3.2. For hydraulic equipments

3.2.1 Hydraulic oil yank

1． Press type air filter

2． Level-meter
3． Oil tank
4． Oil return filter
5． Oil suction filter

15
3.2.2 Main pump
——PSVD2-27E(B0600-27013)

Parameters
discharge Cm3/rev 36+36
P1 and P2 pump
rated pressure MPa 30.5
discharge Cm3/rev 10
pilot pump
pilot pressure MPa 4.0
discharge Cm3/rev 28
P3 pump
rated pressure MPa 25
rated rotational speed r.p.m 2200

weight kg 36

16
Bolt tightening torque
ITEM
Description Size Tightening torque N-m
NO.
1 Screw M5 5.9 ±%10
2 Orifice M5 2.45 ±%10
3 Nut M10 15.7±%10
4 Bolt,SCH M12 106.9±%10
5 Plug PF 3/8 57.0 ±%10
6 Plug PF 1/4 29.4 ±%10
7 Set screw M12 3.92 ±%10
8 Bolt,SCH M10 44.1 ±%10

17
18
3.2.3 Swing motor
MSG-44P-21(B0250-44015)
Discharge 44.1lml/rev
Overflow valve setting pressure 23.5 MPa at 70.5L/min (backing pressure is 0.3MPa)
Leaking pressure Normal: less than 0.1Mpa Instant: less than 0.3 Mpa
Braking pressure less than 1.5MPa; Max.: 3.9MPa
Hydraulic oil ISO VG 46
Temperature range -20-90

Swing motor oil port

Oil port A- motor oil- in/out port

Oil port B- motor oil- in/out port
Oil port M- motor feed port
Oil port DB- leaking port
Oil port PB- motor relieve braking port
Oil port GA/GB-A&B pressure testing port

19
Motor schematic diagram

Motor structure diagram

20
3.2.4 Multiple unit valve
Specification: KVMM80-WA

Main valve schematic diagram

21
Pump / main valve pressure oil distribution

1. section BUCKET
2. section BOOM1
P1
3. section TRAVEL-R
4. section ARM2
5. section TRAVEL-L
P2
6. section BOOM2
7. section ARM1 P2
8. section AUX. P2
9. section DOZER
P3
10. section SLEW

22
23
3.2.5 Center swing joint

Notes:
port A-left travel motor P1 port(G1/2) port B-left travel motor P2 port(G1/2)
port C-right travel motor P1 port(G1/2) port D-right travel motor P2 port(G1/2)
port E-blade cylinder piston(G1/4) port F-blade cylinder rod(G1/4)
port G-two travel motor 2-speed(G1/4) port T-two travel motor leakage(G1/4)

24
3.2.6 Traveling motor
Specification: GM10VA-A
Total discharge: 1speed/2speed 2276/1356 ml/rev
Motor discharge: 1speed/2speed 49.5/ 29.5 ml/rev
Reduction rate: 1/45.97
Highest pressure: 30MPa
Relieve braking pressure: 0.63 MPa
Leaking pressure: Normal: less than 0.1; Max. pressure: less than 0.5
Hydraulic oil: ISO VG32 or equivalent; ISO VG 46，68 or equivalent
Gear oil: GL-4 #90 or equivalent Notes:

Oil port P1/P2- motor oil–in/out port

Oil port T1- motor leaking port
Oil port Ps- motor double speed port
Oil port a1/a2-motor P1/P2 pressure testing port

25
Traveling motor schematic diagram

Traveling motor inner structure diagram

26
3.2.7 Traveling/destroyer foot valve and pilot joystick

1. Traveling duplex foot valve

1
1

P
2
2

27
 Oil port P- traveling foot valve oil –in port
Oil port T- traveling foot valve oil –out port
Oil port 1-going forward control port
Oil port 2- going back control port

2. Destroyer foot valve

Port P- earth-moving foot valve oil-in port

Port T- earth-moving foot valve oil return port
Port 1- dozer blade upwards control port
Port 2- dozer blade downwards control port

28
Earth-moving valve

29
 Port P- earth-moving foot valve oil-in port
Port T- earth-moving foot valve oil-return port
Port 1- dozer blade upwards control port
Port 2- dozer blade downwards control port

3.2.8 Handle lever pilot control valve

30
3.2.9 Hydraulic oil return filter

1． seal ring
2． bottom end cover
3． framework
4． filter bed
5． framework
6． valve

31
3.2.10 Hydraulic oil suction filter

1- filter core 4- nut

2- nut 5- spring
3- connecting rod

3.3. For electric equipments

Specification of electric equipment is divided into following 9 parts:
1. using of conducting wiring and plug
2. power and charging system control
3. engine control
4. hydraulic action control
5. meter monitor system
6. lighting control system
7. wiper control system
8. electric control box
9. other accessory
10. wiring diagram
32
4. Test and adjustment and Failure Diagnosis
4.1. For mechanical structure device
For track tension device
For track plate

Inspection
z Operate controlling lever slowly, lift machine by operation device and dozer blade.
z inspect space A between track frame centre bottom surface and track top surface, space A
shoule be in the range of 190~215 mm.

Note: too much clay, dust or other substance on chassis may lead to inaccurate measuring
result, so clean chassis before measurement.

Adjustment

Add tension
z Take off cover 1.
z Inject grease into grease relief valve 2 by grease gun.
z Check tensity of track.

Reduce tension
z Take off cover 1
z Relieve grease by slowly loosening grease relief valve 2 ,if grease relief is difficult, move
machine forwards or back wards.

33
 z Tighten grease felief valve 2.
z Check tensity of track.

4.2. For hydraulic device

4.2.1 Inspection and adjustment of hydraulic oil circuit of working device, swing and
traveling
(1)
every 10 h every 50 h every 250 h every 500 h every 1000 h
S ervicing activity com ponent
(daily) (w eekly) (6 m onths) (12 m onths) (18 m onths) annual

M O TO R

O il level O
F uel level O
Leakage O
V isual check O
A ir filter O /X <> <>
S eating of m ounting bolts O
C oolant O
E ngine speed regulation O
E xhaust system O
E ngine oil O < > (1) <> <>
O il filter < > (1) <> <>
V -belt: condition and tension O
C ooler fins X
V alve clearance O O
G enerator, starter O
F uel tank X
W ater pum p O
F uel filter O <> <>
C ooling system and hoses O
E lectrical connections O
P re-glow system O
C oolant therm ostat O
B attery fluid O

O — Check <> —Change/Replace

X — Clean <> (1) —Change/Replace the first time

34
 every 10 h every 50 h every 250 h every 500 h every 1000 h
S ervicing activity com ponent
(daily) (w eekly) (6 m onths) (12 m onths) (18 m onths) annual

HYDRAULIC SYSTEM
F astening bolts H ydraulic pum p O
Leakage (lines, pum ps, cylinders) O
H ydraulic oillevel O
O ilcooler fins X
F ilter insert <>(1) O <> <>
P rim ary and secondary pressure
O
lim iting valves
H ydraulic oil O <>(1) <> <>
B reather filter F illing strainer O
ELECTRICAL
Indicator lam ps O
F unction of system O
F astenings O
TRAVEL GEAR
C hain after w orking O
C hain tension O
B earring play of tread rollers,
O
track carrierrollers, front idlers

TRAVEL GEAR UNIT

Leakage O
G ear oil <>(1) <> <>

GEAR RING
B earing system O
G earing <>

O — Check <> —Change/Replace

X — Clean <> (1) —Change/Replace the first time

35
 every 10 h every 50 h every 250 h every 500 h every 1000 h
S ervicing activity com ponent
(daily) (w eekly) (6 m onths) (12 m onths) (18 m onths) annual

HEATING
F unction O
Leakage (cooling and heating
O
circuit)
S eals O
F an O
WORKING EQUIPMENT
Lubricate lubricating points O O
B ucket teeth (fastening and w ear) O
P in fastening O
Line fastenings O
P iston rods O
B ehaviour of hydraulic cylinder
O
under load
B ush bearing play O
B earing play O
GENERAL
O perating elem ents O
H ydraulic fittings O
B olts O
Lights O
W indscreen w ashing system O
Leakage check - visualcheck O

O — Check <> —Change/Replace

X — Clean <> (1) —Change/Replace the first time

36
Maintenance - General (according to Operating Instructions)
‹ The reliability and service-life of machines are to a great extent influenced by care and
maintenance.

‹ Cleaning: In the first 3 months wash the machine only with cold water (no high-pressure or
steam-jet cleaning). After the first three months
‹ the minimum distance between the spraying nozzles and the vehicle must be 30 cm,
‹ and the water temperature shall not be higher than 60°C. Do not use aggressive cleaning
agents.

‹ Therefore, compliance with the specified maintenance work is first of all to the advantage of
the owner of a machine.

‹ Doing the specified maintenance work is made mandatory by the manufacturer. Any default
will lead to restrictions of warranty.

‹ For maintenance work at the engine please cf. the operating instructions for the engine.

‹ If lubricants are used that are not in compliance with the manufacturer’s recommendation
any guarantee becomes extinct.

‹ Before starting maintenance and repair at your vehicle, please get informed about any
damage that occurred.

‹ Before starting maintenance or repair work lower the working equipment to the ground.
Apply locking and safety levers.
- Bleed residual pressure off the hydraulic system.
- Let the engine cool down (hot cooling water).

‹ If work must be done with the machine lifted, it must be appropriately secured (supported).

‹ During maintenance or repair work in a closed room provide for sufficient ventilation.

‹ Dispose of oil filters, oil, etc. as provided by the environmental law.

‹ When working at and/or below the crawler excavator place a warning sign on the driver’s
seat and/or clearly visible and legible at the crawler excavator. Withdraw the ignition key.

37
4.2.2 Lubricants
Lubrication fillings-excavators

38
4.2.3 Hydraulic system
1. General Prerequisites
- Before each pressure test the device must be run up! - Hydraulic oil temperature at least 40°C.
- For hydraulic settings please refer to chapter Technical Data.
- Primary pressure limiting valves must be adjusted at max. engine speed
(See chapter Technical Data).

2. Pressure Test of Variable Displacement Pump P1

Functions: bucket, boom, driving right
a) Apply manometer at measuring port MP 1.
b) Move bucket cylinder to stop (bottom and rod side).
c) Check pressure and/or adjust it at Primary pressure limiting valve at the main valve block.
d) Check the functions boom, driving right by above items a - c.

3. Pressure Test of Variable Displacement Pump P2

Functions: arm, driving left, auxiliary hydraulics
a) Apply manometer at measuring port MP 2.
b) Move dipper stick to stop (bottom and rod side).
c) Check pressure and/or adjust it at pressure reducing valve PRV 2 at the main valve block.
d) Check the functions driving left and auxiliary hydraulics by following items a - c.

4. Pressure Test of Gear Pump P3

Functions: swiveling, dozer blade, auxiliary hydraulics / boom offset
a) Apply manometer at measuring port MPG.
b) Move dozer blade to stop (bottom and rod side).
c) Check pressure and/or adjust it at pressure reducing valve PRV 3 at the main valve block.
d) Check the function auxiliary hydraulics by following items a - c.
e) The swiveling function is supplied by pump 3, though the operating pressure is limited by the
secondary pressure limiting valve at the swivel motor! - See secondary pressures of swivel
motor.

5. Pressure Test of Gear Pump PA,PB (Pilot Pressure)

Functions: hydraulic pilot control
a) Apply manometer at measuring port MPA,MPB.
b) Actuate joystick.
c) Check pressure and/or adjust it at the pressure reducing valve at the control oil unit.

39
Measuring ports at the pump

MP1： P1 pump pressure testing port

MP2： P2 pump pressure testing port
MP3： P3 pump pressure testing port

Position: Main valve block

40
 Doze Quick
working Auxiliar Dflectio
Boom Arm Bucket Swing r chang
pressure(Mpa) y n
blade e
30.5±1. 30.5±1.
Standard
0 0
Adjustme
P nt value
1 Result
decision
Remark
30.5±1. 30.5±1.
Standard
0 0
Adjustme
P nt value
2 Result
decision
Remark
23.5.0±0 25±0.
Standard
.5 5
Adjustme
P nt value
3 Result
decision
Remark
Standard 3.9±0.5
P
4 Adjustme
nt value
Result
decision

41
¾ Gear box
> Check: - Open the oil level plug.
- The oil level must be at the oil level inspection orifice.
> CHANGE: - Open the oil filler and drain plug.
- Drain oil and collect it in an appropriate vessel.
- Close drain plug and open oil level plug.
- Fill in fresh oil via the filler orifice until gear oil emerges from the inspection orifice.
- Close oil level plug and filler orifice.
Warning: It is recommended, as specified in the maintenance schedule, to check leakage
and thus the filling level in the drive unit continually.
Dispose of waste oil as provided by environmental laws.
For gear oil quality - see List of Lubricants (Chapter Technical Data)

filler screw

oil level

drain plug

¾ Hydraulic oil change

The hydraulic oil shall be changed only when warm (approx. 40°C)
Before changing the oil withdraw all hydraulic cylinders.
Turn upper carriage by 90°.

Fig.: Oil drain

plug

42
1) Open breather filter (width across 36) to pressurize tank (tank pressurized).

2) Open drain plug of oil tank carefully (access from below - chassis floor).

3) Drain oil into collecting vessel.

4) Check hydraulic oil tank for contamination and clean it, if necessary.

5) Replace filter according to maintenance instructions.

6) Close screw plug properly again.

7) Fill in clean hydraulic oil via filter station (filtering 10 mµ).

8) Vent hydraulic pump (see chapter Hydraulic Pump).

9) Close hydraulic oil tank properly.

10) Let machine run idle for several minutes.

Dispose of old oil as provided by environmental laws.

¾ Diesel engine
Tab.：Maintenance intervals “500 ”.
To save costs - Sunward can offer an extension for the maintenance intervals of the
excavator
Diesel engine oil and oil filter up to 500 work hours!

First Exchange then exchange

interval
Engine oil /
Standard： 50 hrs. 125 - 250 hrs.
filter
Extension:
Engine oil /
500 hrs. 50 hrs. 500 hrs.
filter
Interval：

To extend the maintenance interval of the diesel engine oil / -filter up to 500 hours - the
following points have to be fulfilled!

A) For every excavator:

- In case of extreme working conditions (high dust concentration, high temperature,
Hydraulic hammer) the maintenance still has to be done with the standard schedule.

43
- The first exchange of the engine oil and filter still has to be done after 50 work hours.
- The engine oil and filter have to be exchanged min. once a year !

B) The extended maintenance interval up to 500 hrs. is only valid for excavators with Yanmar
engines!. Further the following points have to be fulfilled:
- First exchange of the engine oil and filter after 50 hrs.
- No modifications at the diesel engine or its cooling system.
- Only original Sunward or Yanmar filters are accepted!
- Engine oil of quality API-CE4/SG or API-CF has to be used.

4.3. For electric equipments

Main performance parameters and malfunction diagnosis of electric control system
4.3.1 Summary
z Electric control system block diagram

44
45
z Attentions in using and maintenance of electric
equipment
1. Using of conducting wiring and plug
Conducting wiring consists of wire used to connect
elements, plug used connect or cut off wire, other wire
protector and wire duct. Be different from other electric
element installed in box or tank, conducting wiring is apt
to be influenced by rain, water, heat and vibration. In
addition, in inspection and maintenance, conducting
wiring needed to be detached and assembled frequently, so
it may be damaged or deformed. Pay attention when using
conducting wiring.
2. Main malfunction of conducting wiring
①. Poor conduct of plug (poor conduct of plug and plug
seat)
Inproper connection of plug and plug base, poor
alignment due to distortion of plug. Corrosion or oxidation
of contacting surface can result in poor contact.
②. defective pressure welding or braze welding
Pins of connector and pins of plugs contact at
pressure welding terminal or braze welding place.
Overstress may result in disconnection, poor connection
and rupture.
③. disconnection of wire
Holding wire to disconnect connector or lifting parts
connected with wire by crane, or heavy loads crashing onto
wire can result in partial peel-off ,welding port damage or
wire rupture.

④.High pressure enter into connector

Connecor is of water proof(immersion proof), in case
it is being spraied by pressurized water, there is a possiblity
that water will access to connector. The connector is less
subject to access of water due to it’s water proof structure.
But it’s difficult to drain the water. In case of access of
water, dry the connector immediately or take other
measures before energizing.

⑤. Oil or dirt on connector

If there is any trace of oil in presence on connector, or
a oil film is formed on contact surface of plug, a bad connection will occur due to the
non-conductive property of oil. Wipe oil, grease or dirt off the connector with dry rag. Or you
could use pressed air to blow to dry, apply restored agent to it.
46
★ when conneting plug, handle lightly with care, overstress will cause pins to distort.
★ in case that oil or water exists in pressed air, contact point will become even dirtier. So it’s
necessary to remove oil and water before using pressed air
to clean up.

3. Connector and wire harness assembly, disassembly

and dryness
1) Connector disassembly
① During disassembly, hold connection by hand.
When disassembly, it’s connector to be held by hand
not the wire. If the connector is fixed by screw, fully
loosen the screw and hold connector by one hand, plug by
the other hand, pull them apart with equal force. The
connector has a lock chip. Press the chip with thumb to
push connector.
★ never pull with one hand.
② Disassembly from terminal
When removing connector from terminal, pull
connector off terminal horizontally with equal force.
★ Failure to do so will cause damages to shell.
③ Disposal of disassembled connector
After disassembly, wrap it with plastic bag to prevent
dust, oil, water from entry into connector.
★ If the machine is expected to be stored for a long term,
it’s subject to bad connection. So it’s necessary to put
them in bag.

2) Assembly connector
①Connector appearance inspection
Ⅰ. Check the pins for oil, dirt or water.
Ⅱ. Check the pins for distortion, bad connection, rust and
damage.
Ⅲ. Check the connector appearance for damage or
rupture.
★ in case of oil, water or dirt in existence, wipe them off
with rag. In case that water has accessed inside connector,
dry it with air blower. But pay attention not to make it
overheating, this may cause short circuit.
★ If connector is damaged or ruptured, replace with new
one.
② Secure connector
Align with connector properly, secure it into connector. If the connector is fitted with lock
chip, press and push connector till the chip makes an engaging clack sound.
47
③ Rubber case hump and wire harness dislocation redress.
It’s necessary to redress connector with rubber case
as well as to set harness and wire clip in position.
★ If it is difficult to redress, remove the wire clip to adjust
its position.
④If wire clip is removed, do not forget to position it back,
and then check it for any looseness.
3) Dry wire harness
If there is oil or dirt in existence, wipe it off with rag.
Do not use water or vapor to clean them up. In case of any
water has access into connector, carry out following
steps：
① disassemble connector and wipe off water with dry rag.
★ It’s dangerous to blow connector to dry with air.
Because the oil existing in air can cause bad connection,
always use pressed air free of oil to blow for drying.
② use drier to dry connector
In case that water has reached connector, you could
dry it by means of drying device.
★ It’s an good means that use drier to dry connector. But
the connector and its attachments are subject to distortion
and damage under heat. Pay attention to drying time.
③ conduct connectivity test.
With connector dried, while harness is in dismantled
status, conduct connectivity test. Check pins for any
short-circuit due to water.
★ with connector fully dried, apply restored agent and reassemble them.
z Instructions of electric malfunction diagnosis
1) Shut down power source before plugging or unplugging connector.
2) Check all connectors to ensure they are connected properly prior to failure diagnosis.
★ plug or unplug relevant connector several times to carry out an inspection.
3) Before attempting next step, plug connector which has been unplugged.
★ If power source has been switched on, yet connector is still unplugged, abnormal display will
occur.
4) When carrying out inspection operation to circuit (measure voltage, resistance, connectivity or
current), move corresponding circuit and connector several times to check whether the value
being presented in meters would change or not.
★ If changes, bad connection of circuit is suspected.

48
5) Inspection before failure diagnosis.
NO. Items Criterion Remedy
1 Check terminal of accumulator for looseness, — Tighten or
corrosion. replace
2 Check terminal of alternator for wiring looseness, — Tighten or
and corrosion. replace
3 Check terminal of starting motor for wiring — Tighten or
looseness, corrosion. replace
4 Check accumulator voltage(engine lose power) 11.5~14V replace
6 Check battery electric eye (green indicates — replace
sufficient electric power, for white, it needs to
charge.
7 Check wire for fading, burn, and peeling off. — Renew or
replace
8 Check wire clip for peeling off, check wire for — Repair
suspension.
9 Check wire for wet. (Check connector and — Remove
terminal with care). connector to
dry
10 Check fuse for blown out or rust. — Replace
11 Check alternator’ voltage (engine runs over semi- After running a Replace
accelerograph condition). few minutes:
voltage is
13V~14.5V
12 Check noise of accumulator’s relay, while it’s — Replace
running (switch to ON/OFF position alternately).
13 Check pin on electrical box for looseness, check — Repair
wire for looseness, rupture.

4.3.2 Power supply and charging system control

(1) Power supply and charging system parts parameters

Power source parts include accumulator, engine etc. individual parts data is as follow：

Description Electrical data

Accumulator 12V 120Ah
Alternator (Stator coil resistance)resistance 0.108Ω
(Rotor coil resistance)resistance 3.45Ω
Electromagnetic coil resistance 14-17Ω
power main switch

49
(2) Power supply and charging circuit schematic diagram

50
(3) Power supply charging system normal malfunction
This machine is equipped with integral alternator, its actual piece and schematic diagram is as
follow:

The terminal B+ is current outlet line of engine.

Terminal P is alternator signal, it’s commonly within AC 7—9V, it’s being used to be engine
RPM signal and to prevent restart-up.
Terminal IG is field power supply wire of engine. Therefore, alternator can be active only if
IG is energized IG.
Terminal L is corresponding to charging indicator. It’s low resistance if not charging, it’s
high resistance if charging.
You can see in the fight fig, terminal B+ must connect positive polarity. In case the battery
is connected inversely. Damages will occur to commutation diode.
If malfunction happens, inspection operation will cover the following items:
-Check engine belt to ensure proper tension, depress in the middle of the belt with thumb,
the preferred flexivity is about 10mm.
-Check terminal B+ to ensure it’s connected securely with battery.
-Check IG to ensure it’s properly energized.
If no problem is detected by carrying out the troubleshooting procedure above, a problem of
engine is highly suspected. A further analysis is needed.

51
52
4.3.3 Engine control
(1) Engine control parts include: starter, fuel suction pump, fuel cut-off valve, control relay and
pull relay etc.
The parameters are as follow：
Description Electrical parameter
Starter Pull solenoid resistance 0.218Ω
Hold solenoid resistance 0.6Ω
Fuel suction Max current: 1.5A. max pressure: 37.3KPa(0.38kgf/cm2)
pump
Fuel cut-off Pull solenoid current 37A
valve. Hold solenoid current 1A
Control relay 12V，40A
Pull relay 12V，40A

(2) Start system circuit

53
(3) Common malfunction of starting circuit

The key has been switched to starting position, starter no reaction: firstly, check power
source to ensure it’s properly functioning.
Then short circuit terminal of “power source” with relay terminal. If it works, either faulty
control circuit of starter or starter malfunction.
Weak running of starter: check battery voltage to ensure proper function. Check main circuit
connection for looseness.
Main reason of starter slip is one-way clutch slipping.

54
4.3.4 Hydraulic action control
(1) Hydraulic action control related electrical parts and parameter
Hydraulic action control related electrical parts include control switch, solenoid valve etc.
they control pilot solenoid valve and selection valve.
Main parameters：
Rated Resistance
Item Power(W) Current(A)
voltage(V) value(Ω)
Pilot solenoid valve DC12V 36W 3.01 4
Fast step solenoid
DC12V 36W 3.01 4
valve

55
(2) Action control circuit diagram

(3) Selector valve switch harness and connector

56
 Switch panel diagram Pilot switch connector

1—fast/slow step switch 2— destroyer switch

(4) Common malfunction analysis

malfunction Causes Remedy

1 pilot switch Repair or replace
malfunction
2 pilot solenoid Repair or replace
valve malfunction
Pilot no action
3 poor wire Repair
connection
4 electrical control Check pilot relay, fuse of low pressure valve
case malfunction and pilot solenoid valve, repair or replace
1 fuse burns out Replace fuse of low pressure valve
2 fast step solenoid Replace
valve malfunction
Fast travel fails
3 poor wire Repair
connection
4 faulty switch Repair or replace

4.3.5 Meter monitor system

(1) System structure and parts parameters
Monitoring system is being used to check individual sensor and to reflect machine status.
All collected signals are processed and displayed on the meter panel to identify machine’s
condition.

57
Display zone: water temperature meter, oil temperature meter, oil level meter, hour meter and
rational speed meter in sequence
Alarm zone: charge, air filter, oil pressure, greasy dirt, water temperature, preheating, auto idle
speed and noise damping in sequence
Key zone: left, right, auto idle speed, noise damping, upwards, downwards, menu/confirm and
exit in sequence

1) Instructions
Water temperature meter: L/C simulation arc real time display. When water temperature attains
to setting alarming point (104C), signal will flash, and alarming red light is turned on, and buzzer
rings, and also with literal alarming display.

Oil level meter: L/C simulation arc real time display. Signal will flash when level is lower than
10%, and also with literal alarming display.

Hour meter: L/C real time display (contain one bit radix point)

Oil temperature meter: L/C simulation arc real time display. Signal will flash, and alarming red
light is turned on, and buzzer rings, also with literal alarming display when temperature is higher
than 90C.

Charging indication: when alternator does not generate power, signal will flash, also with literal
alarming display.

58
Air filter alarming: when filter is choked, alarming red light is turned on, and buzzer rings, also
with literal alarming display and record.

Oil filter alarming: when filter is choked, alarming red light is turned on, and buzzer rings, also
with literal alarming display and record.

Preheat instruction: input power, light will be lighted, also with literal instruction.

Auto idle speed: press auto idle speed button, light will be lighted, the function will be started,
press the button again, the function will be closed.

Oil pressure alarming: the light will be lighted, buzzer rings, also with literal instruction and
record.
2) Adaptable environmental condition
Working temperature: -20—65℃
Storage temperature: -30—85℃
Relative humidity: <90％
3) Key instructions:
Menu button: Together with upwards/downwards key and left/right key and confirming key
Noise damping key: when alarming appears, press this button, and the light will be lighted.
It has no effect when no alarm appears.
4) User code setting: Initial code is 888888(user can change it), users can set time and reset stage
hour meter using this code.
5) Meter interface port definition
16 holes plug jacket

59
 4 holes plug jacket

Definition:

Black: negative pole Brown: oil filter signal

Red: positive pole Orange: air filter switch signal
Green: fuel level signal Blue: preheat
White: engine water temperature signal Red white: power output
Yellow black: hydraulic oil temperature green white: auto idle speed input
Yellow: rotational speed Red green: auto idle speed output
Purple: charging signal white purple: 485correspondence A
Red blue: water temperature switch signal Red yellow: 485 correspondence B
Red black: oil pressure switch signal

(2) Monitor circuit schematic diagram

60
61
(3) malfunction diagnosis
Problem Cause Remedy
Display 1.defective wire of sensor repair
Engine constantly 2.defective sensor or loose Repair or replace
coolant terminal connector
temperature Always 1.defective sensor replace
gauge. display full 2. short circuit in sensor or Repair or replace
scale grounding wire
Always 1.defective wiring of sensor repair
display full 2.defective sensor or loose Repair or replace
Fuel level scale terminal connector
gauge Always 1.defective sensor replace
display 2. short circuit in sensor or Repair or replace
zero level grounding wire
No rpm 1.defective wiring repair
Revs. 2.engine malfunction Repair or replace
Low rpm loose alternator belt adjust
Air filter Air filter 1.air filter clogging Replace filter
clogging clogging 2.air filter clogging open repair
alarm alarm
Oil filter Oil filter 1short circuit in grounding wire repair
clogging clogging 2 oil filter clogging Replace filter
alarm alarm
No display 1.defective wiring of power service
2.internal malfunction of meter replace

62
4.3.6 A/C system control ( Yizhou SH14)
(1) Electric control and parameters
Electric control includes A/C control switch (A/C switch and wind speed switch), air blast,
govern resistance, amplifier, high/low pressure switch and compressor electromagnetic clutch.
The parameters are as follows:
NO. Name Electrical Specification
1 Blower assy. Working current ＜8A, rated power 90W

Speed governor Resistance between red and yellow line 0.5 +0.3.
2
resistance assy. Resistance between blue and yellow line: 1.0+0.3

Electromagnetic
3 Rated power 41W, resistance value: 3.4Ω
clutch
5.3KΩ/5℃, 3.3KΩ/15℃
Temperature
4 2.1 KΩ/25℃,1.4KΩ/35℃
sensor
Tolerance: + 1%
OFF: pressure ≤0.196MPa or pressure ≥3.14MPa
5 Pressure switch
ON:196 MPa＜ pressure ＜3.14MPa
Air conditioning OFF：resistance ∝
6 Control panel
ON： resistance 3K～0Ω
Rated power：10A
Based on electric schematic drawing, use exclusive
7 Amplifier method (check temperature sensor, air conditioning
switch, ground wire for output) to evaluate amplifier’s
function.

(2) Air conditioning system schematic diagram

63
4.3.7 light control system
(1) Composition and main parameters
Light control system includes boom light, side light, front headlight, indoor light, alarm
light and control push button switch and fuse.
Main technical parameter：
Item Rated voltage Power Remark
Boom light DC12V 55W
Rear headlight (option) DC12V 55W option
Front headlight DC12V 55W
Alarm light DC12V 10W option
Indoor lamp DC12V 10W

64
Push button switch harness

push button switch diagram

① front headlight switch

② side light switch
③ boom light switch
④ alarming light switch

65
(2) light control circuit diagram

66
67
4.3.8 Wiper control system
(1) composition and main parameters
Wiper control system includes wiper controller, wiper motor, scrubber, wiper switch and
washer switch etc.

Wiper control system harness

NO. Code Name Wire Wire

NO. color
1 FLRY0.75 scrubber control 28 pink
FLRY0.75 Scrubber engine
2 105 orange
positive pole(+)
FLRY0.75 interval 5s grass
3 29
controller green
4 FLRY0.75 wiper engine reset 102 brown
FLRY0.75 wiper engine
5 104 blue
inversion
FLRY0.75 wiper engine
6 103 green
positive rotation
FLRY0.75 wiper engine
7 100 purple
positive control
FLRY0.75 wiper engine
8 101 white
negative control
FLRY0.75 Power positive
9 51 red
pole(+)
FLRY0.75 single speed Yellow
10 30
control green
FLRY0.75 Power negative
11 0 black
pole (—)

68
 NO. Code Name Wire Wire
NO. color
wiper engine
1 FLRY0.75 100 purple
positive control
wiper engine
2 FLRY0.75 101 white
negative control
3 FLRY0.75 wiper engine reset 102 brown
wiper engine
4 FLRY0.75 104 blue
inversion
wiper engine
5 FLRY0.75 103 green
positive rotation

Wiper switch panel and harness

69
 wiper engine wiper controller
wiper switch

70
Wiper control system circuit diagram

scrubber switch
scrubber
(2)
4.3.9 Electric control box
Electric control box consists of relay and fuse
Panel diagram

71
 Connector of bottom plate arrangement

Fuse catalog

NO. Connector electric Fuse capacity Remark

appliance
1 oil pump fuse 20A
2 radio 10A
3 light 15A front light
4 cigar lighter 10A
5 spare parts 20A
6 meter 10A
7 low pressure valve 10A
8 A/C 20A
9 wiper 15A
10 indoor light alarming
top lighter 10A
light
11 pilot 10A pilot solenoid valve
12 light 10A boom light
13 horn 10A
14 lighter lock 10A

72
 Relay catalog

NO. Name Mode Capacity Remark

1 Start relay 4191008 70A, DC12V
2 Safety relay HG4190 40A(NO), DC12V
3 Pilot relay HG4190 40A(NO), DC12V
4 Preheating relay HG4191 70A , DC12V
5 Light relay HG4190 40A , DC12V
6 Light relay HG4190 40A , DC12V
7 Horn relay HG4190 40A , DC12V

4.3.10 GPS control system

GPS wiring diagram

GPS diagnosis and process

1. Analysis and remedy according to problems

No. Problem Cause Remedy

Contact with GPS controller
No power a、 Machine locked
1 GPS Measure 3A,3B with multimeter，
supply b、Defective GPS
replace GPS if it is not through.
Contact with GPS controller
a、 Machine locked No.9 line has no voltage, switch on
Fail to start
b、GPS no power GPS power
2 up(engine no
supply Measure 6A, 6B with multimeter when
action)
c、 Defective GPS start up ， replace GPS if it is not
through.

73
 No. Problem Cause Remedy
No
Contact with GPS controller
movement of a、 Machine locked
3 Measure 52B、52A with multimeter，
whole b、Defective GPS
replace GPS if it is not through.
machine
Contact with GPS controller
a、 Machine locked
4 flameout Measure 4A、4B with multimeter，
b、Defective GPS
replace GPS if it is not through.

2. Analysis and remedy according to meter displayed locked information

Displayed Simply judgment and

No. Fault analysis
content remedy
Long-distance lock Contact with GPS
1 GPS lock 001
code controller
Contact with GPS
controller. If there is no
need to lock, GPS
Lock code for long
2 GPS lock 002 controller provides the
time no GPRS signal
code; it can be
unlocked by meter or
display.
Contact with GPS
Lock code for GPS
3 GPS lock 003 controller and replace
antenna wire- break
GPS
Contact with GPS
GPS anti-demolition controller ，it will be
4 GPS lock 004
lock code unlocked automatically
after full installation.
Contact with GPS
Lock code for controller
interrupt 1 、 check bus wiring
5 GPS lock 005 communication harness. 2、check GPS
between GPS and power supply.3、replace
meter or controller GPS.4、replace meter or
controller.

It is generally adopt delay lock manner to lock the machine. Lock will be displayed firstly,
and then machine will be locked as engine start again after flameout (except for GPS lock 005.
After communication being interrupted for 1 minute, it suggests lock will be active after 5
minutes. Machine is locked after 5 minutes. )
74
 3. Replace GPS
(1) Detach failed GPS
(2) Confirm that the replacing GPS has same model number with replaced one.
(3) Install GPS on appointed place with fasteners. Connect 12-core connector with wiring
harness. Put the front face of antenna upward and fix it with glue;
(4) Inform the GPS controllers of the Customer Service Dept. Make test according to the
GPS testing procedure.
(5) Mark the fault phenomena about the removal GPS and send them back to the company
together with the corresponding equipments.

4.3.11 Other attachments

1．Auto idle speed equipment
It includes pressure switch, auto idle speed device and meter auto idle enabled switch.

75
 When auto idle speed does not act, throttle is adjusted by idle speed device through stay
wire.
When auto idle speed enabled switch acts, and pressure switch installed on pilot hydraulic
pipeline inspects the low pressure (no hydraulic parts act), after meter receive the signal of
pressure switch, it make inner engine rotate to put the throttle turn back to idle position by 72#
wire.
When hydraulic parts act, pressure switch inspect the pressure, the device will be adjusted
to position set by the knob by meter control.
2．Preheating control
When the key is pull to start or preheating, engine preheater will be controlled by
preheating controller, and the preheating signal will show the preheating situation buy meter
display, and it will cut off power to avoid overheating when preheating time is attained.

76
3． Radio
It includes radio control wire, horn and antenna.

77
78
5. Disassembly and assembly
5.1. How to read this manual
Installation and removal of assy.
Parts Removal
z Section “removal” includes procedure and instruction.
z All the warning signs and marks which have been used in the section “removal” are listed as
follow:
★ This mark is used to provide instruction and attention to operating procedure.

Parts installation
z Install parts in reverse order unless otherwise noted.
z All marks and signs used in section “installation” is as follow:
★ This mark is used to provide instruction and attention to operating procedure.

Assembly and disassembly of assy.

Disassembly
z Section ”disassembly” includes procedure and instruction.
z All the warning signs and marks which have been use in this section “disassembly” are
listed as follow.
★ This mark is used to provide instruction and attention to operating procedure.

Assembly
z This section “assembly” includes procedure, precaution and know-how.
z All the sighs and marks are explained and listed as follow:
★ This mark is used to provide instruction and attention to operating procedure.

1. Instructions during disassembling

You must obey following items when detach or install equipments.
Attentions when detach equipments:
z Dispose properly if engine coolant contains anti-freezing fluid.
z Always cap or plug hoses when hoses or steel pipes are removed to prevent them from entry
of dirt, dust and debris.
z Provide a proper container to catch the oil discharged
z Provide mating marks to avoid re-assembling mistake, prior to disassembling.
z Do not pull conducting wire to avoid loose from contact point. When disconnecting
conduct wire, Hold connector to avoid excessive force applied to wire.
z Attach marks on the wire or hose to make certain their position. it helps to avoid mistake
during re-assembling.
z Calculate and inspect the number and thickness of washers, and keep them at safe place.
z Make certain to use proper lifting device with sufficient strength and reliability, when lifting
components.
79
z Evenly fasten screw in proper sequence when lifting bolt was used to remove any
components.
z When disassembling any devices, clean the surrounding area and cover them to prevent dust
or dirt from entering into them.
★ Instructions when working with pipeline during disassembling.
During the process of disassembly, please insert the blind plug into the pipe after the
pipeline is disassembled.

2. Instructions during the process of assembly

z Fasten all the nuts and bolts with specified torque value.
z No distortion or interference is allowed during hose installation.
z Replace all bushing, o-ring, cotter pin, and locking plate with new ones.
z Securely bent cotter pin and locking plate.
z When applying bonding compound, Clean components and remove all oil and grease. And
then apply 2 or 3 drops to all parts with thread.
z When applying sealant, clean surface and remove all oil and grease. If no dirt and damages
are recognized, evenly apply sealant to it.
z Remove or repair all part’s damage, dent, burrs and rust.
z Grease all rotary components or sliding components.
z Apply anti-friction composites to the part surface, when press- fitting
z Make certain snap rings have been securely located in the groove. After assembling snap
rings.
z Make wire connector free of oil, dirt and water, connect securely when connecting wire with
wire connector.
z When using eye bolt, inspect it to make certain the bolt free of distortion and metamorphic.
Make sure to completely fasten it and align it with the lifting hook.
z When fastening counter flange, always fasten them evenly to prevent that one side’s flange
is over fastened.
★ After the cylinder, main pump and other hydraulic devices are disassembled and
repaired then re-assembled, bleed the air for the first time use. The operation procedure is
as follow:

1) Start the engine and run it with low idle speed.

2) Operate working device controller to operate hydraulic cylinder 4-5 times, stop the cylinder
at a position 100 mm away from the stroke end
3) Operate hydraulic cylinder 3-4 times to its stroke end.
4) Make the engine run with normal speed, afterwards.
★ When using the machine for the first time after long-term storage or repair, follow
the same procedure.

80
3. Instruction after operation：
z In the event that engine coolant is drained, tighten drain valve, refill coolant to specified
level. Run the engine to cycle coolant in system then check the fluid level.
z In the event that hydraulic device has been disassembled then re-assembled, refill oil to the
specified level. Run the engine to cycle oil in the system. Then check oil level.
z If repair and disassembly to pipelines or hydraulic devices are made, bleed the air after
re-assembling components
z Apply grease with specified volume to relevant parts of working device.
5.2. Radiator assy. Assembly and disassembly
Tools
NO. Code Name Specification
1 ESB400060037 Ratchet wheel spanner 3901

2 740119000013 Torque spanner NB-200

3 740105000003 Sleeve 10 13 17 22

4 740115000023 13-16

5 740115000003 double – end spanner 17-19

6 740115000032 16-18

7 740119010065 SH22D×17
open head of Torque spanner
9 740119010067 SH22D×22
75X5GB
4 740121000010 Cross screwdriver
1064-89

(1) Detachment: in inverse sequence of installation

★ Detached pipeline joints oil ports should be sealed in time, and seal parts should be
stored well.

(2) Installation
1）Cooling device split charging
a. As the figure show, dust-proof screen mounting plate 4 and dust-proof screen 3 is installed
between radiator 1 and condenser 2, seal pad is in order and firm. Assemble radiator and
condenser together using bolts. Connect left/right bracket 5 , 6 with condenser 2 using bolts and
fix them.

81
b. fix air ducting plate 10 and air damper module 8 using bolts, install water pipe clamp 27 ,
auxiliary water tank 11 and water ducting pipe, stick heat insulation sponge 31 on air damper
module, and stick upper and right heat insulation sponge 29 and 30 on radiator.

2）Cooling device assembly

a. stick rubber sheet CR on platform, and fix cooler on platform using bolts, nut and shock
absorber 7,8,9.
b. install shield 6, and fix it with bolts.
c. install water-in pipe 1 and water-out pipe 5, and connect engine with water-in port and water-
out port of water tank using bar clasp.
82
3) A/C pipeline connecting
According to corresponding joints: connect them to compressor , dry bottle and main
machine, as the figure show.

4) Hydraulic pipeline connecting:

Oil return pipe 1→oil return block; oil return pipe 2back to oil tank directly (as the figure
show)

83
5.3. Hydraulic pump assembly and disassembly
(1) special tools
NO. Code Name Specification
Ratchet
1 ESB400060037 wheel 3901
spanner
Torque
2 740119000013 NB-200
spanner
3 740105000003 Sleeve 10 13 16 17 18 22

4 740115000023 13-16
double–end
5 740115000003 17-19
spanner
6 740115000032 16-18

7 740119010059 SH15DX17
open head of
8 740119010063 Torque SH19DX27
spanner
9 740119010065 SH22DX32

84
(2) Detachment: in inverse sequence of installation
★ Detached pipeline joints oil ports should be sealed in time, and seal parts should be stored
well.
Assembly:
1． Shaft coupling assembly:
1) Install shaft coupling b into engine flywheel plate a and tighten bolts c.

2) As the figure show, tighten mounting bolts according to sequence 1→2→3→4→5→6→7→8

2．Connecting plate and main pump installation:

1) As the picture show, tighten mounting bolts 2, and fix connecting plate 1 according to cross
method (torque: 65N.m)
2)Outer tooth of main pump and main shaft should be matched shaft coupling inner tooth and be
insert into it.(torque:200N.m)
3) Fix the duplex gear pump 4 on hydraulic pump and tighten it using bolts 6.(torque: :65 N.m)

85
4). Install O ring into the groove of oil suction steel pipe 21, and make it stick on groove outer
ring, and then fix oil suction steel pipe on main pump oil suction oil port (torque: 110Nm).
Tighten oil suction pipe with steel pipe using bar clasp 17; hydraulic oil enter hydraulic pump
through oil tank.

5). Main pump joints mounting: joint 1 torque 45 Nm, joint 2 torque 60Nm. Mounting place, see
the figure.

86
3. Hydraulic pump pipeline connection (as figure show)
a. main pump1#hose(P3)→multiple unit valve P3 port(hose end tightening torque: 105N.m)；
b. main pump 2# hose(P2)→multiple unit valve P2 port(hose end tightening torque: 135N.m).
c. main pump 3# hose(P1)→multiple unit valve P1 port(hose end tightening torque: 135N.m)；
d. main pump 4# hose(P4)→filter IN port

87
5.4. Slewing motor and slewing mechanism assembly and disassembly
(1) special tools
NO. Code Name Specification
Ratchet wheel
1 ESB400060037 3901
spanner
2 740119000013 Torque spanner NB-200
13 16 17 18
3 740105000003 Sleeve
22 27
4 740115000003 17-19
double –end
5 740115000024 22-24
spanner
6 740115000020 30-32

7 740119010059 SH15DX17
open head of
8 740119010063 SH19DX27
Torque spanner
9 740119010065 SH22DX32

(2) Detachment: in inverse sequence of installation

★Detached pipeline joints oil ports should be sealed in time, and seal parts should be stored
well.

(3) Assembly
1．swing motor split charging:
T3(M)、DB、A、B main oil port and pilot PB oil port joints mounting，tightening torques
are as follows:
Motor oil –in/out port
Oil port B- motor oil-in/out port, torque 40N.m
oil port M-motor oil feed port，torque 45 N.m
Oil port DB- oil leaking oil port
Oil port PB- motor brake relief oil port
Oil port GA/GB-A&B pressure testing oil port

88
2．swing motor mounting:
1). fix swing motor on platform using bolts 2 as the figure show, the gears should meshed
correctly, then fix motor and make its installation surface be jointed and preinstall bolt 2. 2).
Tighten bolts after motor is installed (torque: 270N.m)

2) After swing motor is installed into platform, use bolt 2 to tighten it symmetrically, and tighten
mounting bolts (torque: 270N.m)
3. Swing motor pipeline connecting:

89
pipeline 1: multiple unit valve A9→swing motor A port(hose end tightening torque: 45N.m).
pipeline 2: multiple unit valve B9→swing motor B port(hose end tightening torque:45N.m).
pipeline 3: swing motor M→oil return block(2)oil feed 1# port(hose end tightening torque::
60N.m).

pipeline 4: swing motor(1)DB port→ centre swing connector(2) to T port(hose end tightening
torque::30N.m).
pipeline 5: swing motor(1)PB port→ accumulator C port(hose end tightening torque: 30N.m).

5.5. Carrier roller installation and removal

(1) Detachment: in inverse sequence of installation

Special tools
NO. Code Name Specification
Pneumatic TOKUMI-16
1 740119000017
wrench 12.5
Torque
2 740119000011 NB-300
wrench
3 740105000010 Sleeve 18
(2) Assembly:
Carrier roller 1 installation:
a. Install carrier roller 1 into chassis mounting plate 4, and tighten it with bolts and elastic pad 2,
3. ( torque: 113N.m)
b. Ensure dimension (m=1mm) in figure after bolts tightening.

90
5.6. Slewing bearing assembly and disassembly
Special tools:

NO. Code Name Specification

Pneumatic TOKUMI-16
1 740119000017
wrench 12.5
Torque
2 740119000011 NB-300
wrench
3 740105000010 Sleeve 24

4 Eye ring M16

(1) Detachment: in inverse sequence of installation

(2) Assembly:
1）Clean chassis swing bearing installation surface until the surface appears metal polish,
mounting surface 1 should be spread with sealant 2 (sealant model number: 1596)

91
2) Put eye ring 4, 5 into swing bearing hole for hoist and tighten it, and make the hook 2 of sling
chain 1 to hook eye ring 4, 5.

3) Weak points refer to outer space weak points 1 and inner space weak point 2.

3）Rotate swing bearing and make outer space weak point 1 towards right direction of the
machine (be opposite with s label); make inner space weak point 2 towards left direction; bolt 3
should be installed into mounting hole of swing bearing 4, and tighten the bolt, torque 270N.m
(see the picture)
92
4）Tighten bolt according to sequence (1)→(2)→(3)→(4)group, other bolts should be installed
into swing bearing 4 in turn.

Torque after pre-tightening refer to figure a.

93
5.7. Central swing joint assembly and disassembly
(1) special tools
NO. Code Name Specification
Ratchet wheel
1 ESB400060037 3901
spanner
2 740150000013 Long extension rod 125mm
16 17 19
3 740105000003 Sleeve
22
4 740115000003 double –end 17-19

5 740115000024 spanner 22-24

(2) Detachment: in inverse sequence of installation
★ Detached pipeline joints oil ports should be sealed in time, and seal parts should be stored
well.

(3) Installation
1）Fix centre swing joint 1 onto bottom frame seat plate 2 using bolt 3, bolt torque 110N.m

94
a. bottom oil port joints mounting:
A’, B’,C’, D’, E’, F’ oil port joints mounting(tightening torque：70N.m).
G’, T’ oil port joints mounting(tightening torque：45、30N.m).

b. top oil port joints mounting:

A, B, C, D, E, F oil port joints mounting (tightening torque: 70N.m).
G, T oil port joints mounting(tightening torque: 45、30N.m).

95
2) Centre swing joint→multiple unit valve traveling, earthmoving main pipeline connecting(see
picture)
Pipeline 1: centre swing joint A port→multiple unit valve B3 port
Pipeline 2: centre swing joint B port→multiple unit valve A3 port
Pipeline 3: centre swing joint C port→multiple unit valve B4 port
Pipeline 4: centre swing joint D port→multiple unit valve A4 port
Pipeline 5: centre swing joint E port→multiple unit valve A7 port
Pipeline 6: centre swing joint F port→multiple unit valve B port
Pipeline 7: centre swing joint G port→accumulator A port
Pipeline 8: centre swing joint Tee T port; left side connects with motor B port, right side connects
with oil return tank.

96
5.8. Hydraulic oil tank assembly and disassembly
(1) Detachment: in inverse sequence of installation
★ Detached pipeline joints oil ports should be sealed in time, and seal parts should be stored
well.

Special tools

NO. Code Name Specification

TOKUMI-16
1 740119000017 Pneumatic wrench
12.5
2 740119000013 Torque wrench NB-200

3 740105000003 Sleeve 13 16 18

4 740103000004 Active spanner 300X36

5 740121000004 Cross screwdriver 200X8X1.2

Inner hexagon
6 740104000007 S10
spanner
open head of
7 740115000002 double-ended 13-16
spanner

(2) Assembly
1）Clean inside oil tank using dust catcher from port 1 and 2 as the figure shown, and then
inspect and confirm it attains to 11 class cleaning level

97
2）Oil suction assembly
a. Preinstall oil suction filter core 7 into oil suction flange 12, and install O ring 4 into flange seal
groove, make O ring stick to groove outer space.
b. Preinstall oil return filter core 17 into flange3, and install O ring 4 into flange seal groove,
then assemble it according to the picture, and screw it with bolts.
c. Tighten oil suction steel pipe flange 8 and O ring 9 using bolts according to the picture.
d. Fix the pilot oil block 23, oil temperature sensor 1, oil label 21, air filter 13, pressure
communicator 22 onto corresponding position in the picture by bolts.

98
3）Hydraulic oil tank joints mounting
a. Plug 1 mounting; joints 2 mounting, mounting torque 60N.m; joint 6 mounting and tee joint 3
mounting.
b. Joint 4 mounting, torque 25 N.m; joint 5 mounting , torque 60 N.m.

99
5.9. Multiple way valve assembly and disassembly
(1) Detachment: in inverse sequence of installation
★ Detached pipeline joints oil ports should be sealed in time, and seal parts should be stored
well.

Special tools

NO. Code Name Specification

TOKUMI-16
1 740119000017 Pneumatic wrench
12.5
2 740119000013 Torque wrench NB-200
13 16 17 18
3 740105000003 Sleeve
19 22 27 32
4 740119000018 CL200NX17D
Fixing torque open
5 740119000019 CL200NX19D
spanner
6 740119000020 CL280NX22D

7 740115000033 19-22
open head of
double-end spanner
8 740106000003 24-27

(2) Assembly
1）a. main valve pilot joint mounting (as the figure show)

100
b. main valve main pipeline joints mounting:
in the figure: joint 1, joint 2, joint 3 ——tightening torque: 40N.m
in the figure: joint 5 ——tightening torque: 60 N.m
in the figure: joint 6, joint 7, joint 8 ——tightening torque: 60 N.m

c. main valve main pipeline joints mounting:

in the figure: joint 1, joint 3——tightening torque: 60 N.m
in the figure: joint 2, joint 5——tightening torque: 40 N.m

101
2) Connection of main valve and working device (following figure shown)

102
5.10. Pilot control valve disassembly and assembly
Special tools

NO. Code Name Specification

Pneumatic TOKUMI-16
1 740119000017
wrench 12.5
2 740119000030 Torque wrench NB-100

3 740105000003 Sleeve 19
Fixing torque
4 740119000018 CL200NX17D
open spanner

(1) Detachment: in inverse sequence of installation

★ Detached pipeline joints oil ports should be sealed in time, and seal parts should be stored
well.
(2) Assembly

1) Pilot control valve oil port label and joints mounting:

a. Hand lever pilot control valve oil port label and joints mounting:
a.1 Tighten the joints according to sequence 1→2→3→4→T→P
a.2 Oil port 1, 2, 3, 4, T, P ——tightening torque 30N.m

b. Foot pilot control valve oil port label and joints mounting (flowing figure shown)

103
2) Hand lever pilot control valve→pilot pipeline connecting of multiple unit valve:
a. hand lever pilot control valve→oil port pipeline connecting of pilot control unit of multiple
unit valve(following figure shown)

104
b. Earthmoving valve hydraulic parts mounting (following figure shown)

3) Pilot oil-in pipeline connecting (following figure shown)

105
4) Oil collection block pipeline connection (following figure shown)

5.11. Travel motor disassembly and assembly

Special tools

NO. Code Name Specification

TOKUMI-16
1 740119000017 Pneumatic wrench
12.5
2 740119000011 Torque wrench 80－300N.m.
17 19 22
3 740105000003 Sleeve
24
4 740119000018 CL200NX17D
Fixing torque open spanner
5 740119000020 CL280NX22D

7 740115000005 17-19
open head of double-ended spanner
8 740115000033 19-22

106
(1) Detachment: in inverse sequence of installation
★ Detached pipeline joints oil ports should be sealed in time, and seal parts should be stored
well.

(2) Assembly
1) Travel motor mounting:
a. Fix travel motor 20 into chassis motor seat, and through hole should be tighten using bolts on
the cross, and exert torque 240N.m to fix motor.
b. Install driving wheel 18 into motor 20 and match the tap hole, tighten the bolts on the cross,
and the bolts tightening torque 240N.m

2) Oil pipeline connection of travel motor 5 and centre swing centre 6: (tightening torque of hose
ends 45 N.m)

107
6. Attachment drawings and others
6.1. Hydraulic system schematic diagram

108
6.2. Electric system schematic diagram

109