Service Manual of Wheel Loader

Contents
1. General .................................................................................................................. 1-1
11 Precautions before service .................................................................................. 1-1
12 Specification ......................................................................................................... 1-3
121 Specification and torque ................................................................................ 1-3
122 Unit conversion ............................................................................................... 1-5
13 Mark ..................................................................................................................... 1-7
14 Service criterion ................................................................................................... 1-7
141 Visual inspection or touching determination ............................................... 1-7
142 Determination of measurement method ....................................................... 1-8

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Service Manual of Wheel Loader

1. General
11 Precautions before service
Park the loader at the service location.
Hang up warning sign.
In case of service, put the warning sign near the start
button so as to prevent people from starting the
engine.
Accessory preparation
Carry out the service and replacement with repairable
part specified by our company.
Oil preparation
Select oil specified in this manual based on
environment temperature.
Use specified oil.
Keep the oil tank clean and use the specified oil.
Keep the loader clean.
Keep the loader clean, especially the oil injection
parts including oil cup and oil filler so as to prevent
the entrance of impurities.
Pay attention to high-temperature oil and
high-temperature coolant
When the engine stops, it is dangerous to discharge
the high-temperature oil and the coolant or take down
the oil filter. The above operation can only be carried
out after the engine cools down completely. The
proper temperature of oil to be discharged is within
20~40℃. If lower than this temperature, the oil can
only be discharged after being heated to this
temperature.
Check oil and oil filter
After replacing oil or oil filter, check the discharged
oil and the replaced oil filter. Contact the service
personnel if finding a large number of metal particles
or other impurities.
Fuel coarse filter
Do not take down the fuel coarse filter when filling
the fuel.
Replacement of oil
Replace the oil at clean place so as to ensure the oil
not polluted when replaced.

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Service Manual of Wheel Loader
Welding guidance
• Turn off the engine start switch and remove the
battery cable.
• The distance between the welding area and the
earthing cable should be above 1 m.
• Avoid implementing the welding near the seal
ring and the bearing.
• Do not weld the pipeline or tank with oil fluid.
Fire prevention
Clean parts with non-flammable detergent or
ordinary diesel and keep away from spark or
firework.
Sealing element
To replace O-shape ring or sealing gasket, clean the
sealing surface firstly and then install the new
O-shape ring or the sealing gasket into the accurate
position.
Check frame
After shoveling and transporting aggregated rocks for
a long time, check whether the frame is damaged and
whether connecting bolts and nuts of components are
loosened and damaged.
Precautions for cleaning the loader
• The engine should be cleaned after cooling
down completely.
• Do not spray water to the electrical apparatus
element.
Check in rain and snow environments
After the operation in rain and snow environments,
clean the loader immediately and apply lubricating
oil and rust-preventative oil at more components.
Dusty environment
Pay attention to following points when the loader
operates in dusty environment:
• Usually check and clean the air filter to avoid
the blocking.
• Usually clean the radiator to avoid the blocking.
• Usually clean and replace the fuel filter.
• Clean the electric installation, especially the
start motor and the generator, to prevent the
accumulated dust from affecting the radiation.
Refer to the Operation and Maintenance Instructions
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 Service Manual of Wheel Loader
of Diesel Engine attached with the loader for detailed
replacement and maintenance of air filter.
12 Specification
121 Specification and torque

Table 1 Tightening torque of commercial bolt

Strength Yield Nominal diameter of bolt mm

grade of strength 6 8 10 12 14
bolt N/ mm2 Tightening torque N·m
8.8 640 9~12 22~30 45~59 78~104 124~165
10.9 900 13~16 30~36 65~78 110~130 180~210
12.9 1080 16~21 38~51 75~100 131~175 209~278

Strength Yield Nominal diameter of bolt mm

grade of strength 16 18 20 22 24
bolt N/ mm2 Tightening torque N·m
8.8 640 193~257 264~354 376~502 521~683 651~868
10.9 900 280~330 380~450 540~650 740~880 940~1120
12.9 1080 326~434 448~597 635~847 864~1152 1098~1464

Strength Yield Nominal diameter of bolt mm

grade of strength 27 30 33 36 39
bolt N/ mm2 Tightening torque N·m
10.9 900 1400~1650 1700~2000 2473~3298 2800~3350 4111~5481
12.9 1080 1606~2142 2181~2908 2968~3958 3812~5082 4933~6577
Table 1-2 Tightening torque table of bolts used to connect cast iron or aluminum
Bolt grade and torque 8.8 10.9
Torque(N·m) Torque(N·m)
Bolt specification Cast iron Aluminum Cast iron Aluminum
M8 20~25 15~20 28~33 15~20
M10 45~50 25~30 55~60 25~30
M12 70~80 50~55 100~105 50~55
M14 110~125 80~90 150~165 80~90
M16 160~180 120~140 220~240 120~140
M18 205~230 165~180 295~320 165~180

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 Service Manual of Wheel Loader

Table 1-3 Tightening torque of joint body

Joint with copper seal gasket or seal taper thread Joint with O-shape seal ring
Tightening torque
Joint specification Tightening torque N·m Joint specification
N·m
M14, G1/4 34±5 M12×1.5 35±3.5
M18, G3/8 73±10 M14×1.5 45±4.5
M20, G1/2 93±10 M16×1.5 55±5.5
M24 142±20 M18×1.5 70±7.0
M27, G3/4 205±30 M20×1.5 80±8.0
M33, G1 421±49 M22×1.5 110±10
M42 872±98 M27×2.0 170±17
M30 320±40 M33×2.0 310±31

Table 1-4 Tightening torque of 24°taper seal

Tightening torque of 24°taper seal pipe joint nut
Specification Tightening torque (N·m)
M12×1.5 20±5
M14×1.5 30±5
M16×1.5 35±5
M18×1.5 45±5
M20×1.5 50±5
M22×1.5 65±10
M24×1.5 70±10
M26×1.5 85±10
M30×2 115±15
M36×2 145±15
M42×2 210±20

Table 1-5 Tightening torque of hinged bolt

Thread specification Tightening torque (N·m)
M10×1 25~35
M12×1.5 60~75
M14×1.5 80~100
M16×1.5 105~115
M18×1.5 20~130

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 Service Manual of Wheel Loader
M22×1.5 140~155
M24×1.5 160~180
M27×2 190~230
M33×2 270~320

122 Unit conversion

Table 1-6 Length
Unit Centimeter Meter Kilometer Inch Foot Yard Mile
Centimeter 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
Meter 100 1 0.001 39.37 3.2808 1.0936 0.00062
Kilometer 100000 1000 1 39370.7 3280.8 1093.6 0.62137
Inch 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
Foot 30.48 0.3048 0.000304 12 1 0.3333 0.000189
Yard 91.44 0.9144 0.000914 36 3 1 0.000568
Mile 160930 1609.3 1.6093 63360 5280 1760 1
1 millimeter=0.1 centimeter 1 micrometer=0.001 millimeter

Table 1-7 Area

Unit cm2 m2 km2 Acre ft2 yd2 in2
cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
2
m 10000 1 0.000001 0.01 10.764 1.1958 -
2
km - 1000000 1 10000 1076400 1195800 -
Acre 0.01 100 0.0001 1 1076.4 119.58 -
ft2 - 0.092903 - 0.000929 1 0.1111 144.000
yd2 - 0.83613 - 0.008361 9 1 1296.00
2
in 6.4516 0.000645 - - 0.006943 0.000771 1
2 2
1 hectare=100 acre 1 mile =259 hectare=2.59 km

Table 1-8 capacity/volume

Unit cm3 m3 dm3 in3 ft3 yd3
Milliliter 1 0.000001 0.001 0.061024 0.000035 0.000001
Liter 1000000 1 1000 61024 35.315 1.30796
L 1000 0.001 1 61.024 0.035315 0.001308
in3 16.387 0.000016 0.01638 1 0.000578 0.000021
3
ft 28316.8 0.028317 28.317 1728 1 0.03704

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 Service Manual of Wheel Loader
yd3 764529.8 0.76453 764.53 46656 27 1
3 3
1 gallon(American system)=3785.41 cm =231 in =0.83267 gallon(British system)

Table 1-9 Weight

Unit g kg mt Ounce Ib.(pound)
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
mt 1000000 1000 1 35273 2204.59
ounce 28.3495 0.02835 0.000028 1 0.0625
Ib (pound) 453.592 0.45359 0.000454 16 1
1 t(metric system)=1.1023 t(American system)=0.9842 t(British system)

Table 1-10 Pressure

Unit kip/cm2 Bar Pa=N/m2 Kpa Lbf/in2 Lbf/ft2
kip/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
Bar 1.01972 1 100000 0.001 0.00015 0.02086
2
Pa=N/m 0.00001 0.001 1 0.001 0.00015 0.02086
Kpa 0.01020 0.01 1000 1 0.14504 20.886
2
Lbf/in 0.07032 0.0689 6894.76 6.89476 1 144
2
Lbf/ft 0.00047 0.00047 47.88028 0.04788 0.00694 1
2
kg/cm =735.56 dry measure (mmHg) =0.96784 barometric pressure

Table 1-11 Unit description

Unit Abbreviation
Newton meter N·m
Kilopound meter kpm
Kilopascal kPa
Megapascal MPa
Kilowatt kW
Kilojoule kj
Thermal unit in British system Btu
Calorie ca

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 Service Manual of Wheel Loader

13 Mark
To emphasize the importance of safety and quality,
make following marks.

Table 1-12
Mark Item Remark
During the operation, pay special attention to safety.
Safety
When carrying out the operation, pay special attention to
safety because internal pressure exists.
During the operation, pay special attention to technical
Note requirements and ensure the operation quality in conformity
with standards.
Weight or assembling method of component or device. Pay
Weight attention to selecting load lifting device and the posture
during the operation.
Tightening During the assembly, pay special attention to the tightening
torque torque of components
Coating The position needs to be coated with adhesive and grease.

Oil and
Fill certain amount of oil, water and fuel.
water

The place where oil or water is discharged and the discharge

Discharge
amount

14 Service criterion
141 Visual inspection or touching
determination
1. Parts with severe bump, crack, breakage and loss
of function should not be used any more.
2. Oil seal, scraper seal, O-shape ring and seal
gasket disassembled due to leakage, poor
reliability and short life time for reuse should not
be used continuously.
3. Bolt, nut, washer, plug screw and pipe joint with
serious corrosion, un-tightened and damaged
thread, excessive wear and slipping should not be
used continuously.
4. Locking steel wire used to connect bolt should
not be used continuously after being

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 Service Manual of Wheel Loader
disassembled.
5. Bearing not turned flexibly by hand, with cracked
components, worn raceway and damaged ball
should not be used continuously.
6. Gear or spline with crack, sheeting, damage and
excessive wear in teeth should not be used
continuously.
7. Shell with crack and crack, wear, oval and
sheeting in shell bearing mounting hole and shell
thread not tightened normally should not be used
continuously.
8. Bearing seat and oil seal seat with crack, wear,
oval, damage and sheeting in fitting surface/seam
allowance should not be used continuously.
9. Pin with serious wear, damage and crack should
not be used continuously.
10. Implement the primary determination by visual
inspection and smelling. The hydraulic oil should
be replaced if following conditions appear during
use and inspection: milk white, acid smell, yellow
or muddy oil.
142 Determination of measurement
method
Visual inspection or touching cannot be used for
determination, the measurement determination can be
adopted.
Table 1-13
Criteria Measure for
Type of part Inspection item Dimension out of
Allowable limit tolerance
(tolerance)
Internal diameter
About 0~－0.02 +0.02
tolerance
Bearing Replacement
External diameter
About 0~－0.02 －0.04
tolerance
12% of reference circle
Wear in gear gear thickness
Gear About 0~0.10 Replacement
thickness
(usually within 1.2~1.4)
External diameter
Tolerance is Recommendation: less
for ordinary
Ordinary marked as T than lower limit 0.3T
matching Replacement
components
Internal diameter for Tolerance is Recommendation: larger
ordinary matching marked as T than upper limit 0.3T
Fit clearance >0.02 Replacement
Multiple unit
between valve
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 Service Manual of Wheel Loader
valve element and valve
opening
Fit clearance
between valve
>0.02 Replacement
Steering gear element and valve
sleeve
Stator and rotator >0.08 Replacement
Fit clearance
Single
between valve
stabilizer >0.02 Replacement
element and valve
valve
body
Fit clearance
between valve
Priority valve >0.02 Replacement
element and valve
body

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