Lonking CDM816D User manual

Dear users:
Thank you for choosing LONKING CDM816D wheel loader!
This Manual briefly describes safety instructions, performance parameters, structural principle and
requirements for operation, maintenance, adjustment and others of LONKING CDM816D wheel loader
for use and reference of machine operators, servicemen, and technical managers.
The Manual is the guideline for proper machine operation and maintenance; therefore, please read
carefully and comprehend the manual before machine application and operation and strictly follow the
corresponding instructions and requirements for machine operation, lubrication, maintenance and
repair. Many faults are resulted from human factors such as careless reading of Operation Manual;
High safety awareness and proper maintenance guarantee a safe and efficient operation, thus
benefitting you a lot. Therefore, please read and comprehend the safety instructions before operation
and strictly follow the relevant instructions and requirements. Incorrect operation, lubrication,
maintenance and repair are dangerous and may cause personal casualties.
Since we will continuously strive to improve product quality and synthesis performance to achieve
better cost performance and higher working efficiency, the information in this manual will be changed
without notice.
The technical parameters involved in this manual will not be taken as the inspection or test
basis of the third party.
In order to better service you and improve product and service quality, please inform us by
correspondence of the problems and improvement comments found when using LONKING products
and their Operation Manual.
This is the first edition.
Best wishes for your business!
LONKING (Shanghai) Road Construction Machinery Co., Ltd.
Jan. 30, 2012

Foreword
Documentation
Operation & Maintenance Manual shall be properly preserved in the cab for review at any time. Read
and comprehend this manual by all means.
This manual may not incorporate contents generated due to continuous product improvement and
update.
Some structures or accessories shown on photos or pictures in this manual may be different from
those on your machine.
In case of any doubts about the machine or this manual, please consult the LONKING dealers for the
latest information.
Manual structure
This maintenance manual consists of 7 parts: forward, safety (Chapter I), product information (Chapter
II), operation (Chapter III), maintenance (Chapter IV), hoisting of loader& loaderfixing in transportation
(Chapter V), common malfunctions and troubleshooting (Chapter VI) and reference table for densities
of common materials.
Safety
This part lists a series of basic safety preventions, various warning labels as well as their respective
content and position applied.
Product information
This part lists the usage, performance and parameters of the product.
Operation
This part describes the instruments, switches, control mechanism of machine and tooling as well as
materials on transportation and towing.
Maintenance
This part specifies the maintenance cycle of all machine parts. The items given in the Table of
Maintenance Cycle shall be done within the specified cycle. The items without the specification for
maintenance cycle shall be listed under the “maintenance when necessary”.
Attached table
Reference Table for Densities of Common Materials

Contents
Chapter I. Safety.............................................................................................................................................................................................................................................................1
I. Safety instructions........................................................................................................................................... 1
Chapter II Applications, Main Technical Performance and Parameters................................................................................................... 14
I. Applications................................................................................................................................................ 14
II. Overallperformance parameters.......................................................................................................................... 14
III. Engine...................................................................................................................................................... 15
IV. Powertrain.................................................................................................................................................. 15
V. Brakingsystem............................................................................................................................................. 16
VI. Steering hydraulic system................................................................................................................................. 17
VII. Working hydraulic system................................................................................................................................. 17
VIII. Electrical system........................................................................................................................................... 17
Chapter III Operation......................................................................................................................................................... 19
I. Control mechanism and instrument...................................................................................................................... 19
II. New vehicle running-in.................................................................................................................................... 20
III. Operation of wheel loader................................................................................................................................. 21
IV. Lubrication.................................................................................................................................................. 29
Chapter IV Structures of Main Components................................................................................................................................ 31
I. Diesel engine............................................................................................................................................... 31
II. Hydraulic torque converter................................................................................................................................ 31
III. Transmission............................................................................................................................................... 32
IV. Drive axle................................................................................................................................................... 34
V. Hydraulic steering system................................................................................................................................. 37
VI. Implementhydraulic system............................................................................................................................... 39
VII. Implement&frame.......................................................................................................................................... 47
VIII. Braking system............................................................................................................................................. 49
IX. Electrical system........................................................................................................................................... 56
I. Lubrication.................................................................................................................................................. 58
II. Regular maintenance...................................................................................................................................... 59
Chapter V Instructions for Loader Fixing in Hoisting and Transportation................................................................................................. 69
I. Hoisting of loader......................................................................................................................................... 69
II. Fixing of loader in transportation......................................................................................................................... 69
III. Shipping of loader.......................................................................................................................................... 70
Chapter VI Common Faults and Solutions.................................................................................................................................. 71
Attached Table：Reference Table for Densities of Common Materials................................................................................................................................................................75
"H"字体变一致

CDM816D WHEEL LOADER
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Chapter I. Safety
I. Safety instructions
Failure to follow or completely follow the basic safety regulations during the operation, maintenance or
repair is the chief plotter for frequent accidents. Therefore, always keeping the safety awareness is a
guarantee for accident elimination.
The operators of this machine shall possess high safety awareness and strong sense of responsibility
as well as have received adequatetrainings in safety rules, operating skills, usage of machine and
tools, emergency troubleshooting and other aspects so as to be capable for machine operation.
To ensure your safety, please do not make any maneuver to this machine unless you have carefully
read and comprehend the Operation& Maintenance Manual.
Improper machine operation, maintenance or repair is dangerous and likely to cause casualties!
The machine is applied with various safety warning labels, which are described in this Manual in detail.
If you fails to pay due attention to them, each operation step will possibly lead to irretrievable damage
to yourself or others.
Each kind of possible danger has been identified by safety warning labels like “Warning”, “Danger” or
“Caution” applied on the machine with corresponding hint provided, as per which you can take correct
measures; absolutely, we cannot predict all kinds of possible dangers in reality. Therefore, it is
necessary to remind the machine operators to ensure the safety of themselves and others as well as
prevent the machine against any damage or breakage.
Danger:
Definition to the label heading:
①There exist dangers possibly threatening your personal safety;
②Do not operate arbitrarily; any action may influence the normal performance of machine as well as
cause machine damage or dangerous accidents.
Warning:
Definition to heading of “Warning”:
①There exist potential dangers possibly threatening your and others’ personal safety;
②Do not operate arbitrarily; any improper operation may lead to machine damage or influence its

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2
normal performance.
Caution:
Definition to heading of “Caution”:
①There exist dangers possibly threatening your personal safety;
②Please operate as per the instructions; any incorrect operation or non-operation may influence the
normal performance of machine or damage it.
Correct operation, maintenance and repair are essential for a higher operating efficiency and
application safety.
The information and relevant pictures provided in this manual are the most accurate during its
preparation but may be changed due to the prolonging of its service time and the constant product
improvement. The machine owner shall pay attention to any information changes and timely inform
them to the operator. It is a must to obtain the most accurate information and material about the
machine before maintenance, repair or operation; in case of any difficulties hereinto, please consult
the local LONKING sales-service department for those information or material.
Prior to maintenance or repair, please carefully read and fully comprehend the relevant safety
instructions; failure to pay sufficient attention to those instructions may cause injuries or even death to
yourself or others; the relevant safety instructions can be referenced in the following documents:
★Safety labels applied on the machine or its interior parts
★This manual
★Accessory catalog of the overall unit
★Operation & Maintenance Manual of Machine Accessories
★Accessory Catalog of Machine Accessories
★Specific Safety Instructions distributed by LONKING Holdings Limited
The followings describe the safety rules in terms of basic operation, maintenance and repair procedure.
Always abide by those provisions for correct machine operation, maintenance and repair.
Always abide by those provisions for correct machine operation, maintenance and repair:
1.1 Safety hints
1.1.1 The machine may be operated only by the trained, qualified and designated personnel.
1.1.2 Most accidents in the operation, maintenance and repair of products are caused by the
non-compliance with the basic safety rules or precautions. If the potential dangers can be recognized
in advance, the accidents may always be avoided. The staff shall be warned of a variety of potential
dangers and trained for the necessary skills and the correct operating methods.

CDM816D WHEEL LOADER
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1.1.3 Incorrect operation, maintenance or repair is dangerous and may cause personnel
casualties.
1.1.4 After power-on but before startup, please sound the horn twice to alarm the people around to
watch out, for the loader is ready to start; the loader is shut down electrically under the control of key.
For this purpose, shift to the ”OFF” position and keep for 3-5s; return to the power-off gear to cut off the
power after the engine has been stopped, and then take out the key to avoid electricity leakage and
other accidents. Always remember to disconnect the power when parking to ensure the safety of
personnel and machine; cut off the master power switch after each operation to avoid electricity
leakage.
1.1.5 Unauthorized modification to the machine may damage its functions or weaken the safety
and influence its service life.
1.1.6 In case of any machine faults, please have it repaired at the designated special service
center and purchase the special LONKING accessories.
1.1.7 Please use the LONKING special oil when replacing or refilling with oil (grease); notice that
the fuel tank is on the right side in the forward direction of the machine and the hydraulic oil tank on the
left side. When servicing (refilling with) oil, never mix the oils at different grades and from different
manufacturers together; it is a must to apply the LONKING special brake fluid, for the inacceptable
brake fluid may lead tobrake locking, insufficient braking force or brake failure, thus causing machine
non-operation and even safety accidents.
1.1.8 If the brake plate of the caliper brake has been worn for 2/3, replace it with a new acceptable
one; or else, braking may be failed.
1.1.9 Do not adjust the set pressure of the hydraulic system on your own.
1.1.10 The vehicle speed shall be slowed down to lower than 4km/h upon shoveling and loading
materials. Never insert the bucket into the material by means of impact force and never lift the boom
mandatorily when the bucket has not been retracted; or else, the machine parts may be damaged
seriously.
1.1.11 It is a must to park the vehicle and shift to neutral position before changing the driving
direction (from forward to backward or vice versa) to prevent the transmission parts from damage due
to inertia impact of machine parts.
1.1.12 During the long-distance transfer by yourself, keep driving at medium/low speed and never
drive at high speed.
1.1.13 When topping up or performing repair, pay highly attention to keeping the cleanness of oil
(grease) and machine parts; or else, the system may be so contaminated to accelerate the machine
wear and even substantially shorten the machine service life.
1.1.14 Replace the damaged protective sleeves immediately to avoid other serious malfunctions.
1.1.15 Safety precautions and warnings are included in the manual and product. The ignorance of
these warnings may lead to the personal casualties and economic losses of yourself or others.
1.1.16 Dangers shall be identified with the “safety warning symbols” and such “label texts” as
"Danger", "Warning" and "Caution".

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1.1.17 The model shall not work in a contaminated environment.
1.1.18 The model does not apply to the environment subject to falling objects.
1.1.19 Always check the operating handle before starting the machine to ensure that the handle is at
the neutral position.
1.1.20 The left door of cab is for entrance/exit (the forward direction is positive) and the right door is
for emergency exit.
1.1.21 Lower the boom and bucket on the ground before shutting down the engine except in special
conditions.
1.1.22 Properly support the lifted boom (if required) during repair.
1.2 Safety labels
1.2.1 There are special safety labels sticking to your machine, and their accurate location and
corresponding dangers will be described in this part in detail. Please familiarize yourself with the safety
labels before operation.
1.2.2 Ensure that all safety labels are clear and legible.
1.2.3 Clean or replace the illegible safety labels.
1.2.4 Replace the label with illegible icon.
1.2.5 To clean the safety labels, use cloth, water and soap instead of solvent, gasoline or other
aggressive chemicals which may cause adhesiveness loss of the sticking agent for label application
and even shedding of safety labels from the machine.
1.2.6 Replace any damaged and missing safety labels.
1.2.7 If the replaced part is applied with safety label, reapply the label on the new part.
1.2.8 Various brand-new safety labels are available at any LONKING after-sales facilities.
1.3 Understanding signal words
1.3.1 On safety labels, the words indicating the danger degree - DANGER, WARNING or
CAUTION - are used together with the safety marks. "Danger" refers to the immediate danger and
may cause death or serious personnel injury if not avoided.
1.3.2 “Warning” refers to the existence of potential
dangers, which may cause casualties if not avoided.
Fig. 1

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1.3.3 “Caution” refers to the existence of potential
dangers, which may cause light or medium injury if not
avoided.
Fig. 2
1.3.4 "Danger" or "Warning" safety labels are set near the specific hazard areas. For the
conventional safety protections, see "Caution" labels.
1.3.5 Some safety labels include the words not mentioned above after the safety warning marks
have been used on the machine.
1.4 Schematic diagram for layout of safety labels and additional labels
Fig. 3
Warning label for boom (1)
Location: outside the left plate of boom
Location of fuel tank
label

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Never stand under the lifted boom; or else, serious
damages or even death are possibly caused.
Fig. 3-1
Safety label of hinge (2)
Label location: outside the main plate of front frame of loader
Risk of crushing. Do not stand here when the vehicle
makes turning. Otherwise, injury or death may be
caused due to crushing. Always lock the bogies of
front and rear frames when transporting loader or
repairing the hinges.
Before the wheel loader returns to work, remove the
steering lock device and put it away.
Fig. 3-2

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Label for hydraulic oil (3)
Label location: near the round dipstick of left hydraulic oil tank in the forward direction of overall unit.
Refill with the hydraulic oil in time to avoid loader stop;
incorrect oil filling may disenable or even damage the
machine.
Fig. 3-3
Label for user warning (4)
Label location: left rear of cab seat
Always operate the machine as per the label;
otherwise, machine damage or personal injuries may
be caused.
Fig. 3-4