Lonking CDM835EV.00I User manual

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PREFACE
Thank you for purchasing LONKING’s wheel loader!
This Manual briefly describes the safety, operational and maintenance requirements of
CDM835E Ⅴ.00I/CDM835E Ⅹ.00I wheel loaders for the use and reference by operators,
maintenance and technical management personnel.
Operation Manual is a guide for proper use and maintenance of this machine. Please
carefully read and understand the contents of this Manual before operating this machine.
Please put this Manual in driver’s cab for convenience of reference at any moment. If you
lose this Manual, please contact our sales department for buying a new one.
Many failures arise as a result of operator’s failure to carefully read this Manual and other
human reasons. A high sense of safety and good maintenance enable the safe and
efficient operation of this machine, thus bringing you more benefits. Therefore, please
read and understand safety instructions before operating this machine and fully comply
with them. Improper operation, lubrication, maintenance and repair of this machine are
dangerous and may result in human casualties.
We will continue to increase the working efficiency of the machine by improving product
design and endeavoring to improve the comprehensive product performances. The
parameters and configurations of the machine in this Manual are subject to change
without notice. The technical parameters contained herein shall not serve as the basis for
any inspection or test.
In order to offer better services to you and improve product and service quality, you are
expected to timely inform us of any problem identified during your use of LONKING
products and this Manual, along with any corresponding improvement opinions.
This Manual is its first version (No. 60900003039).
Best wishes for your business!
LONKING Holdings Limited
September 2015

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CONTENTS
PREFACE.......................................................................................................................................... 1
CONTENTS.......................................................................................................................................2
CHAPTER I SAFETY PRECAUTIONS...............................................................................7
1.1 DESCRIPTION OF SAFETY SIGNS.................................................................. 7
1.2 DESCRIPTION AND LOCATIONS OF SAFETY SIGNS.................................7
1.2.1 WARNING SIGN OF REVERSING..........................................................8
1.2.2 WARNING SIGN OF THE ANTI- FREEZE FLUID................................ 8
1.2.3 WARNING SIGN OF MAINTENANCE AND TRANSPORTATION..... 8
1.2.4 WARNING SIGN OF LIFT ARM............................................................... 9
1.2.5 SAFETY WARNING SIGN OF HINGE....................................................9
1.2.6 WARNING SIGN OF FAN....................................................................... 10
1.2.7 WARNING SIGN OF NO TRAMPLE..................................................... 10
1.2.8 DISTRIBUTING DIAGRAM OF GREASE NIPPLE AND
LUBRICATING POINTS......................................................................... 10
1.2.9 MACHINE NAMEPLATE........................................................................11
1.2.10 LIFTING AND BINDING SIGN..............................................................11
1.2.11 HYDRAULIC OIL SIGN..........................................................................12
1.2.12 SCHEMATIC DIAGRAM OF USE OF TRIANGLE IRON................ 12
1.2.13 FUEL SIGN.............................................................................................. 12
1.2.14 WARNING SIGN FOR SCRAPING.....................................................13
1.2.15 ATTACHMENT NAMEPLATE............................................................... 13
1.2.16 SIGN OF FLUSHER CONTAINER...................................................... 13
1.2.17 WARNING SIGN OF PREVENTING SINKING MOVEMENT........ 14
1.2.18 SAFETY EXIT SIGN.............................................................................. 14
1.2.19 SCALDING WARNING SIGN AT HIGH TEMPERATURE PLACE 14
1.2.20 REMARKS FOR LONG TIME STANDSTILL..................................... 15
1.2.21 SIGN OF BATTERY CONNECTING WIRE....................................... 15
1.2.22 COMBINATION OF WARNING SIGNS.............................................. 16
1.3 UNAUTHORIZED MODIFICATION..................................................................... 17
1.4 GENERAL SAFETY PRECAUTIONS................................................................. 17
1.4.1 SAFETY REGULATIONS........................................................................ 17
1.4.2 PROTECTIVE DEVICES.........................................................................18
1.4.3 SAFETY PRECAUTION FOR INTERNAL CAB.................................. 18
1.4.4 WORKING CLOTHES AND PERSONAL PROTECTIVE
EQUIPMENTS............................................................................................19
1.4.5 GETTING ON AND OFF THE MACHINE.............................................20
1.4.6 FIRE PREVENTION OF OIL PRODUCTS...........................................21
1.4.7 PRECAUTIONS WHEN OPERATING AT HIGH TEMPERATURE.. 22
1.4.8 PROTECTION OF ASBESTOS DUST HAZARD................................22
1.4.9 FACE MASK AND EARPLUG................................................................ 23

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1.4.10 FIRE EXTINGUISHER AND FIRST-AID KIT..................................... 23
1.4.11 PREVENTION OF ROLLING INJURY OR CUT OFF...................... 23
1.4.12 ETHER (IF YOUR MACHINE IS EQUIPPED WITH ETHER COLD
STARTING DEVICE).............................................................................24
1.4.13 MAKE SURE A GOOD VENTILATION WHEN OPERATING IN AN
ENCLOSED SPACE............................................................................. 24
1.4.14 PIPELINE, HARD PIPE AND FLEXIBLE PIPE................................. 25
1.4.15 COOLANT................................................................................................26
1.4.16 PROTECTION FROM FALLING OR FLYING OBJECTS................26
1.5 SAFETY PRECAUTION OF OPERATION......................................................... 27
1.5.1 SITE SAFETY......................................................................................... 27
1.5.2 CHECK BEFORE ENGINE START-UP.............................................. 28
1.5.3 ENGINE START-UP............................................................................... 30
1.5.4 CHECK AFTER ENGINE STARTING UP AND BEFORE MACHINE
OPERATION...........................................................................................31
1.5.5 PRECAUTIONS WHEN THE MACHINE BEGINS TO TRAVEL.... 32
1.5.6 PRECAUTIONS WHEN THE MACHINE IS TRAVELING............... 32
1.5.7 CHECK WHEN CHANGING DIRECTION......................................... 33
1.5.8 PROHIBITED OPERATION.................................................................. 34
1.5.9 PRECAUTIONS WHEN TRAVELING ON THE SLOPE.................. 34
1.5.10 BEWARE OF HIGH VOLTAGE CABLES........................................... 36
1.6 PRECAUTION FOR OPERATION....................................................................... 37
1.6.1 METHODS OF USING A BRAKE....................................................... 38
1.6.2 PRECAUTIONS WHEN OPERATING ON SNOWY DAYS............38
1.6.3 PRECAUTIONS FOR OPERATION IN COLD AREAS...................38
1.6.4 DO NOT OPERATE THE MACHINE ON SOFT GROUND........... 39
1.6.5 PRECAUTIONS WHEN PARKING THE MACHINE........................40
1.6.6 PRECAUTIONS WHEN LOADING THE MACHINE....................... 40
1.6.7 PRECAUTIONS OF MACHINE TRANSPORTATION..................... 41
1.6.8 PRECAUTIONS FOR DRAG...............................................................41
1.6.9 PRECAUTION FOR USE AND MAINTENANCE
OF THE BATTERY................................................................................ 42
1.6.10 PRECATUTION FOR START-UP WITH BOOSTER CABLE.........43
1.6.11 PRECAUTIONS FOR BATTERY CHARGE......................................44
1.7 MAINTENANCE PRECAUTIONS.............................................................44
1.7.1 FAULT NOTIFICATION.........................................................................44
1.7.2 CLEANING BEFORE REPAIR AND MAINTENANCE.................... 45
1.7.3 KEEP CLEANNESS OF WORKPLACE............................................ 45
1.7.4 DESIGNATION OF RESPONSIBLE PERSON................................ 45
1.7.5 CHECKING WATER LEVEL OF RADIATOR....................................45
1.8 OPERATING BEFORE REPAIR AND MAINTENANCE......................... 46
1.8.1 SUPPORT OF WORKING DEVICE................................................... 46
1.8.2 APPROPRIATE TOOLS....................................................................... 46
1.8.3 REGULAR REPLACEMENT OF CRITICAL SAFETY PARTS...... 47

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1.8.4 ILLUMINATION...................................................................................... 47
1.8.5 FIRE PREVENTION..............................................................................47
1.8.6 PERSONS FOR REPAIR AND MAINTENANCE............................. 48
1.8.7 ATTACHMENTS.................................................................................... 48
1.8.8 MAINTENANCE UNDER MACHINE..................................................49
1.8.9 MAINTENANCE WITH THE FRAME SUPPORTED UP................ 49
1.8.10 MAINTENANCE ON THE TOP OF THE MACHINE........................49
1.8.11 MAINTENANCE WHEN ENGINE IS WORKING............................. 50
1.8.12 NO LEAVING OF FOREIGN MATTER INSIDE MACHINE............51
1.8.13 PRECAUTIONS IN THE USE OF HAMMER................................... 51
1.8.14 WELDING REPAIR............................................................................... 51
1.8.15 PRECAUTIONS FOR BATTERY MAINTENANCE..........................52
1.8.16 TREATMENT OF ABNORMAL STATUS........................................... 52
1.8.17 FILL OF FUEL OR LUBRICATING OIL............................................. 52
1.8.18 HANDLING OF HIGH-PRESSURE HOSE....................................... 53
1.8.19 PRECAUTIONS OF HIGH-PRESSURE OIL.................................... 53
1.8.20 PREVENTION MEASURES OF MAINTENANCE IN HIGH
TEMPERATURE OR HIGH PRESSURE.......................................... 54
1.8.21 WASTE DISPOSAL...............................................................................54
1.8.22 PRECAUTIONS OF TIRE MAINTENANCE......................................54
1.8.23 PRECAUTIONS OF TIRE STORAGE............................................... 56
1.9 CATALOG AND REPLACEMENT CYCLE OF CRITICAL
SAFETY PARTS.............................................................................................. 56
CHAPTER II OPERATION AND CONTROL.................................................................... 58
2.1 MAIN PERFORMANCE PARAMETERS AND SPECIFICATION.............. 59
2.2 OUTLINE DRAWING OF CDM835N WHEEL LOADER............................. 62
2.3 PURPOSE........................................................................................................... 63
CHAPTER III OPERATION INSTRUCTIONS................................................................... 64
3.1 STEERING WHEEL...........................................................................................64
3.2 NEGATIVE-POLE SWITCH OF BATTERY................................................... 64
3.3 STARTER SWITCH........................................................................................... 65
3.4 SERVICE BRAKE PEDAL................................................................................ 66
3.5 ACCELERATOR PEDAL AND INSTRUMENT PANEL ADJUSTING
MECHANISM......................................................................................................67
3.6 GEAR-SHIFT HANDLE..................................................................................... 67
3.7 PILOT JOYSTICK.............................................................................................. 68
3.8 LAMPS AND THEIR SWITCHES.................................................................... 68
3.9 INSTRUMENT ASSEMBLY AND HORN SWITCH.......................................71
3.9.1 INSTRUMENT ASSEMBLY.....................................................................72
3.9.2 HORN SWITCH........................................................................................ 74
3.10 SWITCH OF AIR CONDITIONING SYSTEM................................................74
3.10.1 WARM WATER VALVE..........................................................................75
3.11 SEAT ADJUSTMENT.........................................................................................75
3.12 SAFETY BELT.................................................................................................... 77

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3.13 CAB DOOR LOCK............................................................................................. 77
3.14 USE OF LOCATING LOCK.............................................................................. 77
3.15 ADJUSTMENT TO REAR-VIEW MIRROR....................................................78
3.16 TURNING LAMPS AND FULL-BEAM/LOW-BEAM HEADLIGHTS.......... 78
3.17 CHARGING DOCK............................................................................................ 79
3.18 SUNSHADE........................................................................................................ 79
3.19 PLAYER............................................................................................................... 80
CHAPTER IV OPERATION...................................................................................................82
4.1 NOTICES ON OPERATION OF NEW LOADER......................................82
4.2 RUNNING-IN OF NEW LOADER............................................................... 83
4.2.1 REQUIREMENTS ON RUNNING-IN OF NEW LOADER.............. 83
4.2.2 OPERATIONS TO BE CARRIED OUT AFTER EIGHT HOURS
OF RUNNING-IN................................................................................... 83
4.2.3 OPERATIONS TO BE CARRIED OUT AFTER EXPIRATION
OF RUNNING-PERIODS..................................................................... 84
4.3 OPERATION OF LOADER.......................................................................... 84
4.3.1 INSPECTION BEFORE STARTUP OF ENGINE............................. 84
4.3.2 STARTUP OF ENGINE..........................................................................85
4.3.3 TRAVELLING OF LOADER.................................................................. 86
4.3.4 PARKING OF LOADER......................................................................... 88
4.4 WORKING OF LOADER....................................................................................... 90
4.4.1 PREPARATION BEFORE WORKING............................................... 90
4.4.2 GENERAL TECHNIQUES....................................................................91
4.4.3 WORK METHOD................................................................................... 94
4.5 TRANSPORTATION OF LOADER.......................................................................95
4.5.1 HOISTING OF LOADER...................................................................... 96
4.6 OPERATION IN COLD WEATHER............................................................ 99
4.6.1 PRECAUTIONS FOR OPERATION AT LOW TEMPERATURE... 99
4.6.2 OPERATIONS TO BE CARRIED OUT AFTER COMPLETION OF
WORKS IN EACH DAY...................................................................... 100
4.6.3 AFTER COLD WEATHER HAS ENDED.........................................100
4.7 OPERATION UNDER SPECIAL CONDITIONS.....................................100
4.7.1 OPERATION UNDER EXTREMELY COLD CONDITIONS......... 100
4.7.2 OPERATION UNDER EXTREMELY HOT WEATHER................. 101
4.7.3 PERATION IN DUSTY OR SANDY AREA......................................102
4.7.4 PERATION IN RAINY AND HUMID ENVIRONMENT.................. 103
4.7.5 PERATION IN SALT WATER............................................................ 103
4.7.6 OPERATION AT HIGH ALTITUDE................................................... 103
CHAPTER V MAINTENANCE AND REPAIR................................................................. 105
5.1 PREPARATION BEFORE MAINTENANCE.................................................. 105
5.2 REGULAR MAINTENANCE............................................................................ 105
5.3 LUBRICATION CHART..................................................................................... 114
5.4 THE CHINESE AND FOREIGN OIL TYPE LIST FOR WHEEL LOADER115
5.5 OIL INFORMATION........................................................................................... 116

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5.6 UNIVERSAL TORQUE TABLE........................................................................ 116
5.7 MAINTENANCE OF THE ENGINE COOLANT............................................ 117
5.7.1 COOLANT COMPOSITION............................................................... 118
5.7.2 ADDING COOLANT............................................................................ 119
5.7.3 INSPECT COOLANT LEVEL REGULARLY................................... 120
5.7.4 CLEANING OF COOLING SYSTEM............................................... 121
5.7.5 ENGINE AIR FILTER MAINTENANCE............................................122
5.7.6 MAINTENANCE AND REPLACEMENT OF MAIN CORE
OF THE AIR FILTER...........................................................................122
5.7.7 REPLACEMENT OF SAFE FILTER ELEMENT OF AIR FILTER
124
5.7.8 CLEAN DUST COLLECTION CUP OF THE AIR FILTER............124
5.8 USE OF FUEL SYSTEM AND RELATED MAINTENANCE.......................124
5.8.1 FUEL TANK CLEANING........................................................................124
5.8.2 FUEL OIL LEVEL INSPECTION........................................................ 125
5.8.3 APPLICATION AND REPLACEMENT OF FUEL FILTERS.......... 125
5.8.4 APPLICATION AND REPLACEMENT OF FUEL PRE-FILTERS.125
5.8.5 MAINTENANCE OF ENGINE OIL.....................................................126
5.8.6 REPLACEMENT OF ENGINE OIL....................................................126
5.8.7 REPLACEMENT OF ENGINE OIL FILTER..................................... 127
5.9 INSPECT ELECTRICAL SYSTEM.................................................................... 127
5.9.1 INSPECT BATTERY............................................................................ 128
5.9.2 INSPECT ELECTRICAL DEVICES................................................... 128
5.9.3 SOLDERING........................................................................................ 130
5.10 TRANSMISSION OIL MAINTENANCE................................................... 131
5.10.1 INSPECT OIL LEVEL OF GEARBOX..............................................131
5.10.2 TRANSMISSION OIL REPLACEMENT.......................................... 131
5.11 MAINTENANCE OF DRIVE AXLE OIL................................................... 132
5.11.1 INSPECT OIL LEVEL OF DRIVE AXLE..........................................132
5.11.2 REPLACEMENT OF THE DRIVE AXLE OIL..................................133
5.12 INSPECTION AND REPLACEMENT OF TIRE..................................... 133
5.13 MAINTENANCE FOR LONG TIME PARKING.......................................134
5.14 MAINTENANCE UNDER SPECIAL CONDITIONS...............................134
5.15 MAINTENANCE OF HYDRAULIC OIL........................................................... 135
5.15.1 INSPECT THE OIL LEVEL OF THE HYDRAULIC OIL................ 135
5.15.2 REGULAR REPLACEMENT OF HYDRAULIC OIL...................... 136
5.16 BUCKET MAINTENANCE......................................................................... 137
5.16.1 REPLACE BUCKET O-RING.......................................................... 137
CHAPTER VI COMMON FAULTS AND TROUBLE-SHOOTING................................ 139
CHAPTER VII MAINTENANCE AND SERVICING OF AIR-CONDITIONING SYSTEM 143
CHAPTER VIII ENVIRONMENTAL PROTECTION REQUIREMENT................................ 144
APPENDIX: REFERENCE TABLE OF PROPORTION OF COMMON MATERIALS......145

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CHAPTER I SAFETY PRECAUTIONS
Warning!
Please read and understand all the safety precautions before operation. Failure to do so
may result in severe bodily injury or death.
1.1 DESCRIPTION OF SAFETY SIGNS
Danger!
1) There exists danger that may affect your personal safety.
2) Don’t operate the machine without permission. Any operation may affect the
machine’s normal conditions and cause machine damage or dangerous accident.
Warning!
1) There exists potential danger that may affect the safety of you and others.
2) Don’t operate the machine without permission. Any operation may affect the
machine’s normal conditions and cause machine damage or dangerous accident.
Caution!
1) There exists potential danger that may affect your personal safety.
2) Please operate this machine according to instructions. Any improper operation or no
operation may affect the machine’s normal working conditions and cause machine
damage.
1.2 DESCRIPTION AND LOCATIONS OF SAFETY SIGNS
There are a number of safety signs on the machine. This section will give a detailed
description of their locations and meanings. Please familiarize yourself about these safety
signs before any operation.
If these signs are damaged, lost or illegible after cleaning, please replace them in a timely
manner.
If any part bearing any safety sign has to be replaced, a new safety sign must be affixed
onto the replaced part.

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These safety signs must be kept clean. If the
figures and words on these signs are unclear or
illegible, please replace or clean them with soft
cloth, water or soapy water. No solvent, gasoline
or other irritating chemical agent may be used for
this purpose.
1.2.1 WARNING SIGN OF REVERSING
Sign location: rear counterweight
Contents: when driving the car backwards,
the driver must pay attention to maintain a
certain distance between the machine and
surrounding staff to avoid accidents. When
driving the car backwards, the driver must
pay attention to the surrounding pedestrians
and vehicles to avoid accidents.
1.2.2 WARNING SIGN OF THE ANTI- FREEZE FLUID
Sign location: on the engine hood.
Contents: this sign reminds the user to
operate the machine according to this
sign. Otherwise, it may cause machine
damage or personal injury.
1.2.3 WARNING SIGN OF MAINTENANCE AND TRANSPORTATION

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Sign location: left side of frame hinge joint
Contents: it reminds the users to lock the
frame with fixing rod before transportation
and maintenance of machine, to avoid
accidents. Dismount the fixing rod before the
loader recovers its work, and place it in fixed
location.
1.2.4 WARNING SIGN OF LIFT ARM
Sign location: front end of lift arm
Contents: this sign reminds user that never
permit persons to stand below the moving lift
arm when operating lift arm to avoid
accidents.
1.2.5 SAFETY WARNING SIGN OF HINGE
Sign location: in the front and rear
hinging positions at the left side of
the front frame
Contents:
1. Danger of crushing! Do not stand here when
the loader is turning, because the crushing may
lead to serious injury or death.
2. Danger of crushing! During the transport of
loader or the maintenance of hinge, the front and
rear frames of the loader shall be locked in order
to avoid dangers.

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1.2.6 WARNING SIGN OF FAN
Sign location: at both left and right sides of
the engine hood
Contents: this sign reminds the user to open
engine hood only when the engine stops in
order to avoid severe injury
1.2.7 WARNING SIGN OF NO TRAMPLE
Sign location: upper side of splash guard of
front frame
Contents: due to the limitation of bearing
capacity of steel panel on splashguard, keep
off here to avoid accidents.
1.2.8 DISTRIBUTING DIAGRAM OF GREASE NIPPLE AND LUBRICATING
POINTS
Sign location: left side of the frame hinge
Contents: distribution diagram of lubricating
points by hourly calculation based on the
requirements of machine. This sign reminds
user to fill and change different lubrication
oils at each lubricating point at scheduled
time.