Doosan DL420-3 Wheel Loader Service Repair Manual Instant Download

1
Shop Manual DL420-3 Wheel Loader
Serial Number 10001 and Up
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around
the world.
950106-00437E April 2012
Original Instructions
Copyright DOOSAN 2012
2
Table of Contents
Safety Wheel Loader Safety .......................
..................................................
... SP002397 Specifications Specification for
DL420-3 ..........................................
........................... SP002461 General
Maintenance General Maintenance
Instructions......................................
.................. SP002454 Standard
Torques...........................................
......................................
SP002404 Engine Engine...........................
..................................................
...................... SP002399 Engine Coolant
Heater (Option) ..................................
......................... SP002328 Drivetrain Tra
nsmission and Torque Converter (ZF
4WG-260-4)......................... SP002400
Transmission and Torque Converter (ZF 5WG-260)
(Option) .............. SP002401 Transmission
Error Codes (ZF) .................................
........................... SP002423 Front Axle
(ZF - MT-L 3085 II / 3095 II) ....................
............................ SP002462 Rear Axle
ZF - Multitrac (MT-L 3105 II) ....................
............................ SP002463
Driveshaft........................................
..................................................
.... SP002424 Brake Service Brake
..................................................
.....................................
SP002426 Supply Valve.............................
..................................................
.......... SP002427 Charging Block
..................................................
...................................
SP002428 Parking Brake ...........................
..................................................
.......... SP002429 Brake Pedal Valve
..................................................
.............................. SP002430 Accumulato
r.................................................
......................................... SP002464
Table of Contents Page I
3
Steering Power Steering System ...................
..................................................
... SP002465 Steering Unit .......................
..................................................
................ SP002425 Steering
Pump..............................................
........................................
SP002433 Flow Amplifier ..........................
..................................................
........... SP002434 Jerk Softener and
Accumulator ......................................
...................... SP002435 Emergency
Steering .........................................
....................................
SP002466 Frame Articulation Center
..................................................
.............................. SP002467 Counterwei
ght...............................................
........................................
SP002437 Tank Oil Tank ..........................
..................................................
.................... SP002468 Fuel
Tank..............................................
................................................
SP002469 Hydraulics Main Pump....................
..................................................
...................... SP002470 Main Control
Valve ............................................
................................... SP002441 3rd
Control Valve (Option)............................
........................................
SP002442 Load Isolation System ...................
..................................................
..... SP002536 Cooling System.....................
..................................................
.............. SP002490 Pilot System..............
..................................................
.......................... SP002445 Hydraulic
Schematic (DL420-3)...............................
............................. SP002471 Electrical
System Air Conditioner...........................
..................................................
......... SP002447 Electrical System
..................................................
................................ SP002575
Electrical Schematic DL350-3 / DL420-3 / DL450-3
............................. SP002449
Table of Contents Page II
4
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Wheel Loader
Safety
SP002397
Edition 1
Wheel Loader Safety
SP002397 Page 1
6
Table of Contents Wheel Loader Safety Safety
Instructions .....................................
........... 5 Applicable Models
................................................
5 Safety Messages ................................
.................. 6 General......................
...........................................
6 Transportation .................................
................... 16 Operation..................
..........................................
18 Maintenance ...................................
.................... 36 Environment and
Circumstances........................ 51
Wheel Loader Safety
SP002397 Page 3
7
SAFETY INSTRUCTIONS WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are
necessary before operating or servicing machine.
Read and understand the Operation and
Maintenance Manual and signs (decals) on machine.
Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing.
Check for correct function after adjustments
repairs or service. Untrained operators and
failure to follow instructions can cause death or
serious injury.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DL200-3 10001 and Up
DL220-3 10001 and Up
DL250-3 10001 and Up
DL300-3 10001 and Up
DL350-3 10001 and Up
DL420-3 10001 and Up
DL450-3 10001 and Up
DL550-3 10001 and Up
SP002397 Page 5
Wheel Loader Safety
8
SAFETY MESSAGES Safety messages and safety decals
included in this manual and on the machine
provide instructions how to operate, service and
maintain the machine. Safety messages and
safety decals indicate potential hazards and
describe safety precautions required to avoid
hazards. Operator and maintenance personnel
should read and understand these safety messages
and decals before beginning operation or
maintenance.
SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating
and Safety Instructions. This is a Safety Alert
Symbol. Wherever it appears in this manual or on
safety decals on the machine, you must be alert
to the potential for personal injury or
accidents. Always observe safety
precautions and follow recommended
procedures. Signal Words The signal words
"DANGER", "WARNING", "CAUTION" are used
throughout safety messages and safety decals in
this manual or on the machine. They indicate an
existence of, and the relative seriousness of a
hazard. All three indicate that a safety risk
is involved. Observe the precautions
indicated whenever a Safety Alert Symbol is
present, no matter which signal word appears next
to it.
DANGER
DANGER - This signal word is used on safety
messages and safety labels and indicates an
imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING
WARNING - This signal word is used on safety
messages and safety labels and indicates a
potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION - This signal word is used on safety
messages and safety labels and indicates a
potentially hazardous situation which, if not
avoided, could result in minor or moderate injury.
Wheel Loader Safety Page 6
SP002397
9
SAFETY DECALS Location of safety labels (decals)
can vary from unit to unit. Refer to appropriate
Operation and Maintenance Manual, and parts
manual for your unit. Always replace damaged or
faded decals.
GENERAL
Safe Operation is Operator's Responsibility Only
trained and authorized personnel should
operate and maintain the machine. Follow all
safety rules, regulations and instructions
when operating or performing maintenance on
machine.

• Do not operate machine if you are under
  the influence of drugs or alcohol. An operator
  who is taking prescription drugs must get
  medical advice to determine if he or she
  can safely operate the machine.
• When working with other personnel on a work site,
  be sure that all personnel know the nature of
  work and understand all hand signals that are to
  be used.
• Be sure that all guards and shields are installed
  in their proper location. Have guards and
  shields repaired or replaced immediately if
  damaged.
• Be sure that you understand the use and
  maintenance of all safety features such as pilot
  cutoff switch and seat belt. Use them at all
  times.
• Never remove, modify or disable any safety
  features. Always keep them in good operating
  condition.
• Always check for and know the location of
  underground and overhead utility lines before
  working.
• Failure to use and maintain safety features
  according to instructions in this manual, Safety
  Manual and Shop Manual can result in death or
  serious injury.

Know Your Machine Know how to operate your
machine. Know the purpose of all controls,
gauges, signals, indicators and monitor displays.
Know the rated load capacity, speed range,
braking and steering characteristics, turning
radius and operating clearances. Keep in mind
that rain, snow, ice, loose gravel, soft ground,
slopes etc., can change operating capabilities of
your machine.
SP002397 Page 7
Wheel Loader Safety
10
Engine
SP002399
Edition 2
Engine
SP002399 Page 1
11
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read and understand the Operation and Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments repairs or service. Untrained operators and failure to follow instructions can cause death or serious injury.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DL420-3 10001 and Up
DL450-3 10001 and Up


Engine Page 6
SP002399
12
DC13 ENGINE
FG024616
Figure 1
SP002399 Page 7
Engine
13
ENGINE IDENTIFICATION
Engine Data Plate Applies to engines with
cylinder block generation 2.
Reference Number Description
A Smoke Value
B Engine type
C Engine serial number
A
B
C
FG020225
Figure 3
FG020227
Figure 4
Engine data on plate, on 9 and 13 liter engines
with XPI
2 123 44XX
1 Typ/Type DC 13 06
Variant Motor/Engine No
Reference Number Description
1 Engine Type and Engine Serial Number
2 Engine Serial Number, Stamped
3 Smoke Data
4 Valve Clearance
3
4

FG020228
Figure 5
Engine Page 18
SP002399
14

• Mounting the Engine in a Universal Stand
• Preparations before commencing work
• Remove engine from the machine.

2
3
4
1
FG020231
Figure 6
Reference Number Description
1 Engine Control Unit
2 Fuel Filter
Reference Number Description
3 High-pressure Pump and Feed Pump
4 Starter Motor
1. Mount the engine in the universal stand.
Reference Number Description
1 Bolt M10x30 (8 off)
2 Nut M16 (4 off)
3 Bolt M16x50 (4 off)
2
3 99 331
1
FG020232
Figure 7
SP002399 Page 19
Engine
15
ENGINE SPECIFICATION
ITEMS ITEMS SPECIFICATION
Engine Type 4-Cycle Water Cooled, Waste Gate Turbocharge, Air to Air Intercooled Direct Injection
Engine Emission US EPA Tier 4i (EU Stage IIIB)
Engine Maker and Model SCANIA / DC 13
Engine Injection System Extra high-pressure fuel injection system, XPI
Engine Rated Net Power 264 kW (354 HP) _at_ 1,800 rpm (SAE J1995)
Valve Clearance Intake Valve 0.45 mm
Valve Clearance Exhaust valve 0.70 mm
Number of cylinders and Configuration Number of cylinders and Configuration 6, Straight
Rotating Direction (from Flywheel) Counterclockwise
Oil Pressure (bar, kg/cm²) Normal with the engine at operating temperature, operating speed 3 - 6
Oil Pressure (bar, kg/cm²) Min. permitted at idling speed 0.7
Crankcase pressure with closed crankcase ventilation -55 - 20
Using Lubrication Oil ACEA-E3, E4, E5 or E7 (for fuel with ultra low sulfur)
Oil Filter Paper filter form Scania
Interval between oil changes 500 h
Working Principle 4 Stoke Engine
Cylinder Diameter 130 mm
Piston Stroke 140 mm
Displacement 12.7 dm3
Compression Ratio 17.31
Number of teeth on the flywheel 158
Low Idle Speed 600 - 750 rpm
Max. full load speed 2,100 rpm
Weight, without Coolant and Oil 1050 kg
Cooling System Volume, excluding radiator 16 dm3
Cooling System Coolant Temperature 90 - 95
Cooling System Number of Thermostats 1
Cooling System Thermostat, Opening Temperature 80/87
Electrical System Type 1-pin, 24V, DC
Electrical System Starter Motor (Standard Equipment) 1-pin, 24V, 6 kW
Electrical System Alternator (Standard Equipment) 1-pin, 28V, 100 A
Engine Page 20
SP002399
16
MOTOR Removal and Installation of Motor
NOTE
Replace coolant hoses if there is clear damage to
the coolant hoses which were removed.

1. Drain the oil and coolant.
2. Remove air filter and inlet pipe between the
   turbocharger and air filter. Cover the
   turbocharger inlet pipe.
3. Undo the connections for coolant, charge
   air pipes between engine and charge air cooler,
   and bleed pipe for the expansion tank.
4. Undo the cable harness with clamping.

NOTE
The engine lifting eyes 99 637 are designed for
lifting the engine only, not the engine with
connected equipment (high voltage current
generator, gearbox, reverse gear, etc.) or
frame. All three lifting eyes must be used.
FG020236
Figure 8

• Fasten the lifting chain 98 094 to the rear
  lifting eyes 99
• 637.
• Fasten the lever block 587 308 to the front
  lifting eye.

NOTE
The lifting eyes 99 637 are designed to manage a
maximum inclination angle of 30 when lifting an
engine.
max 30
7. Undo the engine insulator bolts and lift
away/out the engine.
max 20 FG020237
Figure 9
Installing Engine 1. Fasten the lifting chain 98
094 to the rear lifting eyes.
NOTE
The engine lifting eyes 99 637 are designed for
lifting the engine only, not the engine with
connected equipment (high voltage current
generator, gearbox, reverse gear, etc.) or
frame. All three lifting eyes must be used. The
lifting eyes 99 637 are designed to manage a
maximum inclination angle of 30 when lifting an
engine.
max 30
NOTE
max 20

1. Fasten the lever block 587 308 to the front
   lifting eye.
2. Lift the engine, position it on the engine
   insulators and screw it into place.

FG020237
Figure 10
SP002399 Page 21
Engine
17

1. Attach the cable harness with clamping.
2. Install the connections for coolant, charge
   air pipes between engine and charge air cooler,
   and bleed pipe for the expansion tank.
3. Install the air filter and inlet pipe between the
   turbocharger and air filter.
4. Fill with oil and coolant as directed in booklet
   0003-01.
5. Test run the engine to check that no leakage
   occurs. Top up with coolant if necessary.

Engine Page 22
SP002399
18
TIGHTENING TORQUES
Normal Tightening Torque The specifications in
the tables below show the normal tightening
torque for screws, nuts and unions. The values
are to be used unless other values are specified
in the inspection information. Always check
whether there are special tightening torques
given in the descriptions for the respective
areas in the inspection information before
using the general values for normal and
special tightening torques respectively. The
following conditions apply

• A tolerance of 15 applies to all values unless
  otherwise specified.
• All contact surfaces are to be clean and free of
  paint.
• Bolts and nuts are normally not lubricated
  regardless of surface treatment. All exceptions
  are specified in the inspection information.

Union Assemblies The specified values apply with
a tolerance of 5 . The values apply to
tightening with a counterhold. Thread Inserts The
specified tightening torques also apply to bolted
joints with a thread insert (Heli-Coil). Thread
inserts often provide greater strength compared
to a directly screwed thread. This generates a
stronger bolted joint in aluminium or the like.
For this reason, thread inserts are used in
certain joints in Scania's production.
NOTE
When a damaged thread is repaired with a thread
insert, the normal screw and prescribed
tightening torque are to be maintained. Install
the thread insert as instructed in the inspection
information.
SP002399 Page 23
Engine
19
Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts (Metric thread, course pitch) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts (Metric thread, course pitch) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts (Metric thread, course pitch) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts (Metric thread, course pitch) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts (Metric thread, course pitch) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts (Metric thread, course pitch) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts (Metric thread, course pitch) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts (Metric thread, course pitch) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts (Metric thread, course pitch) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts (Metric thread, course pitch)
Thread Strength Class 8.8/8 Tightening Torque (Nm) Strength Class 8.8/8 Tightening Torque (Nm)
M4 2.4 2.4
M5 5 5
M6 8 8
M8 20 20
M10 39 39
M12 70 70
M12 70 70
M14 112 112
M16 180 180
M18 240 240 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238
M20 350 350 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238
M22 490 490 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238
M24 600 600 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238
Flange screws with hexagonal head and hexagonal flange nuts (Metric Thread, Course Pitch) Flange screws with hexagonal head and hexagonal flange nuts (Metric Thread, Course Pitch) Flange screws with hexagonal head and hexagonal flange nuts (Metric Thread, Course Pitch) Flange screws with hexagonal head and hexagonal flange nuts (Metric Thread, Course Pitch) Flange screws with hexagonal head and hexagonal flange nuts (Metric Thread, Course Pitch) Flange screws with hexagonal head and hexagonal flange nuts (Metric Thread, Course Pitch) Flange screws with hexagonal head and hexagonal flange nuts (Metric Thread, Course Pitch) Flange screws with hexagonal head and hexagonal flange nuts (Metric Thread, Course Pitch) Flange screws with hexagonal head and hexagonal flange nuts (Metric Thread, Course Pitch) Flange screws with hexagonal head and hexagonal flange nuts (Metric Thread, Course Pitch)
Thread Strength Class 8.8/8 Tightening Torque (Nm) Strength Class 8.8/8 Tightening Torque (Nm) FG020239 FG020239 FG020239 FG020239 FG020239 FG020239 FG020239
M5 5.4 5.4 FG020239 FG020239 FG020239 FG020239 FG020239 FG020239 FG020239
M6 8.6 8.6 FG020239 FG020239 FG020239 FG020239 FG020239 FG020239 FG020239
M8 22 22 FG020239 FG020239 FG020239 FG020239 FG020239 FG020239 FG020239
M10 42 42 FG020239 FG020239 FG020239 FG020239 FG020239 FG020239 FG020239
M12 77 77 FG020239 FG020239 FG020239 FG020239 FG020239 FG020239 FG020239
M14 123 123 FG020239 FG020239 FG020239 FG020239 FG020239 FG020239 FG020239
M16 184 184 FG020239 FG020239 FG020239 FG020239 FG020239 FG020239 FG020239
Thread forming six-point socket screws and hexagon screws with captive washer (Modified metric thread, course pitch) Thread forming six-point socket screws and hexagon screws with captive washer (Modified metric thread, course pitch) Thread forming six-point socket screws and hexagon screws with captive washer (Modified metric thread, course pitch) Thread forming six-point socket screws and hexagon screws with captive washer (Modified metric thread, course pitch) Thread forming six-point socket screws and hexagon screws with captive washer (Modified metric thread, course pitch) Thread forming six-point socket screws and hexagon screws with captive washer (Modified metric thread, course pitch) Thread forming six-point socket screws and hexagon screws with captive washer (Modified metric thread, course pitch) Thread forming six-point socket screws and hexagon screws with captive washer (Modified metric thread, course pitch) Thread forming six-point socket screws and hexagon screws with captive washer (Modified metric thread, course pitch) Thread forming six-point socket screws and hexagon screws with captive washer (Modified metric thread, course pitch)
Thread Class 8 Class 10
Thread Tightening Torque (Nm) Tightening Torque (Nm)
M4 2.9 -
M6 9.4 11 FG020240 FG020240 FG020240 FG020240 FG020240 FG020240 FG020240
M8 24 26 FG020240 FG020240 FG020240 FG020240 FG020240 FG020240 FG020240
M10 47 49 FG020240 FG020240 FG020240 FG020240 FG020240 FG020240 FG020240
M12 80 85 FG020240 FG020240 FG020240 FG020240 FG020240 FG020240 FG020240
Thread forming six-point socket screws ST thread Thread forming six-point socket screws ST thread Thread forming six-point socket screws ST thread Thread forming six-point socket screws ST thread Thread forming six-point socket screws ST thread Thread forming six-point socket screws ST thread Thread forming six-point socket screws ST thread Thread forming six-point socket screws ST thread Thread forming six-point socket screws ST thread Thread forming six-point socket screws ST thread
Thread Tightening Torque (Nm) Tightening Torque (Nm) FG020241 FG020241 FG020241 FG020241 FG020241 FG020241 FG020241
ST2.9 1.1 1.1 FG020241 FG020241 FG020241 FG020241 FG020241 FG020241 FG020241
ST3.5 1.9 1.9 FG020241 FG020241 FG020241 FG020241 FG020241 FG020241 FG020241
ST4.2 3.1 3.1 FG020241 FG020241 FG020241 FG020241 FG020241 FG020241 FG020241
ST4.8 4.5 4.5 FG020241 FG020241 FG020241 FG020241 FG020241 FG020241 FG020241
ST5.5 7.1 7.1 FG020241 FG020241 FG020241 FG020241 FG020241 FG020241 FG020241
ST6.3 9.7 9.7 FG020241 FG020241 FG020241 FG020241 FG020241 FG020241 FG020241
Engine Page 24
SP002399
20
Stud tap end in threaded hole, strength class 8.8/8 (Metric thread, course pitch) Stud tap end in threaded hole, strength class 8.8/8 (Metric thread, course pitch) Stud tap end in threaded hole, strength class 8.8/8 (Metric thread, course pitch) Stud tap end in threaded hole, strength class 8.8/8 (Metric thread, course pitch) Stud tap end in threaded hole, strength class 8.8/8 (Metric thread, course pitch) Stud tap end in threaded hole, strength class 8.8/8 (Metric thread, course pitch) Stud tap end in threaded hole, strength class 8.8/8 (Metric thread, course pitch) Stud tap end in threaded hole, strength class 8.8/8 (Metric thread, course pitch) Stud tap end in threaded hole, strength class 8.8/8 (Metric thread, course pitch) Stud tap end in threaded hole, strength class 8.8/8 (Metric thread, course pitch) Stud tap end in threaded hole, strength class 8.8/8 (Metric thread, course pitch) Stud tap end in threaded hole, strength class 8.8/8 (Metric thread, course pitch) Stud tap end in threaded hole, strength class 8.8/8 (Metric thread, course pitch)
Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts.
Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts.
Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts.
Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts.
Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Tightening the stud tap end in the threaded hole must be done so the stud does not come loose when undoing the nut. To tighten the stud in the threaded hole, the torque must just overcome the friction in the thread and generate a preload. The torque for locking is 50 of the normal torque for hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. FG020242 FG020242 FG020242 FG020242 FG020242 FG020242 FG020242 FG020242
Union nuts for ferrule Union nuts for ferrule Union nuts for ferrule Union nuts for ferrule Union nuts for ferrule Union nuts for ferrule Union nuts for ferrule Union nuts for ferrule Union nuts for ferrule Union nuts for ferrule Union nuts for ferrule Union nuts for ferrule Union nuts for ferrule
Thread Thread Tightening torque ( 15 Nm) Thread Tightening torque ( 15 Nm) Thread Tightening torque ( 15 Nm) Thread Tightening torque ( 15 Nm)
Thread For pipe diameter Steel pipe with greased steel nut Plastic pipe with steel ferrule and brass or steel nut Plastic pipe with brass ferrule and nut with rubber seal
M10x1 5 15 10 -
M12x1.5 6 20 10 -
M12x1.5 6 20 10 -
M14x1.5 8 30 20 - FG020243 FG020243 FG020243 FG020243 FG020243 FG020243 FG020243 FG020243
M16x1.5 10 40 25 15 FG020243 FG020243 FG020243 FG020243 FG020243 FG020243 FG020243 FG020243
M18x1.5 12 50 30 20 FG020243 FG020243 FG020243 FG020243 FG020243 FG020243 FG020243 FG020243
M20x1.5 12 55 35 - FG020243 FG020243 FG020243 FG020243 FG020243 FG020243 FG020243 FG020243
M24x1.5 16 60 50 40 FG020243 FG020243 FG020243 FG020243 FG020243 FG020243 FG020243 FG020243
M130x2 22 120 - - FG020243 FG020243 FG020243 FG020243 FG020243 FG020243 FG020243 FG020243
Nuts for lead-in union Nuts for lead-in union Nuts for lead-in union Nuts for lead-in union Nuts for lead-in union Nuts for lead-in union Nuts for lead-in union Nuts for lead-in union Nuts for lead-in union Nuts for lead-in union Nuts for lead-in union Nuts for lead-in union Nuts for lead-in union
Thread Thread Tightening Torque ( 15 Nm) Thread Tightening Torque ( 15 Nm) Thread Tightening Torque ( 15 Nm) Thread Tightening Torque ( 15 Nm) FG020244 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244
M12x1.5 20 20 20 20 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244
M14x1.5 25 25 25 25 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244
M16x1.5 35 35 35 35 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244
M18x1.5 50 50 50 50 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244
M24x1.5 70 70 70 70 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244
M130x2 80 80 80 80 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244 FG020244
Unions with tapered thread for port connection Unions with tapered thread for port connection Unions with tapered thread for port connection Unions with tapered thread for port connection Unions with tapered thread for port connection Unions with tapered thread for port connection Unions with tapered thread for port connection Unions with tapered thread for port connection Unions with tapered thread for port connection Unions with tapered thread for port connection Unions with tapered thread for port connection Unions with tapered thread for port connection Unions with tapered thread for port connection
Thread Thread Tightening Torque ( 15 Nm) Thread Tightening Torque ( 15 Nm) Tightening Torque (Nm) Tightening Torque (Nm) FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245
Thread Straight Unions Straight Unions Elbow Unions Elbow Unions FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245
M10x1k 10 10 8 8 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245
M12x1.5k 10 10 8 8 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245
M14x1.5k 15 15 10 10 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245
M16x1.5k 15 15 10 10 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245
M18x1.5k 20 20 15 15 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245
M20x1.5k 25 25 20 20 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245
M22x1.5k 25 25 20 20 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245
M26x1.5k 45 45 40 40 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245 FG020245
SP002399 Page 25
Engine
21
Unions, plugs and banjo screws with cylindrical threads for seal with flat copper gasket Unions, plugs and banjo screws with cylindrical threads for seal with flat copper gasket Unions, plugs and banjo screws with cylindrical threads for seal with flat copper gasket Unions, plugs and banjo screws with cylindrical threads for seal with flat copper gasket
Thread Thread Tightening Torque ( 15 Nm) Thread Tightening Torque ( 15 Nm) FG020246
M8x1 10 10 FG020246
M10x1 20 20 FG020246
M12x1.5 20 20 FG020246
M14x1.5 25 25 FG020246
M16x1.5 30 30 FG020246
M18x1.5 35 35 FG020246
M20x1.5 45 45 FG020246
M22x1.5 50 50 FG020246
M24x1.5 60 60 FG020246
M26x1.5 70 70 FG020246
M28x1.5 80 80 FG020246
M30x1.5 110 110 FG020246
M30x2 115 115 FG020246
M32x1.5 115 115 FG020246
M36x1.5 160 160 FG020246
M38x1.5 170 170 FG020246
M45x1.5 270 270 FG020246
Plugs with tapered thread Plugs with tapered thread Plugs with tapered thread Plugs with tapered thread
Thread Thread Tightening Torque ( 15 Nm) Thread Tightening Torque ( 15 Nm) FG020247
M10x1k 15 15 FG020247
M12x1.5k 20 20 FG020247
M14x1.5k 20 20 FG020247
M16x1.5k 25 25 FG020247
M18x1.5k 40 40 FG020247
M20x1.5k 40 40 FG020247
M22x1.5k 40 40 FG020247
M26x1.5k 60 60 FG020247
Insert connections for port connection Insert connections for port connection Insert connections for port connection Insert connections for port connection
Thread Thread Tightening Torque ( 15 Nm) Thread Tightening Torque ( 15 Nm) FG020248
M10x1k 18 18 FG020248
M12x1.5k 24 24 FG020248
M14x1.5k 28 28 FG020248
M16x1.5k 35 35 FG020248
M22x1.5k 40 40 FG020248
Insert connections for union connection Insert connections for union connection Insert connections for union connection Insert connections for union connection
Thread For pipe diameter Thread Tightening Torque ( 15 Nm) FG020249
M14x1.5k 4-8 10 FG020249
M18x1.5k 12 15 FG020249
M24x1.5k 16 25 FG020249
Engine Page 26
SP002399
22
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Special Tightening Torque The specifications
recommend values for special tightening
torques for certain threaded joints where
there are strict requirements on the
distribution of prestressing force. The
distribution of the tightening torque is 15 and
the clamping force then spread about 30.
Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Applies also with captive washer and hexagon screws with thread cleaning thread. (Metric threads, course pitch) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Applies also with captive washer and hexagon screws with thread cleaning thread. (Metric threads, course pitch) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Applies also with captive washer and hexagon screws with thread cleaning thread. (Metric threads, course pitch) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Applies also with captive washer and hexagon screws with thread cleaning thread. (Metric threads, course pitch) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Applies also with captive washer and hexagon screws with thread cleaning thread. (Metric threads, course pitch) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Applies also with captive washer and hexagon screws with thread cleaning thread. (Metric threads, course pitch) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Applies also with captive washer and hexagon screws with thread cleaning thread. (Metric threads, course pitch) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Applies also with captive washer and hexagon screws with thread cleaning thread. (Metric threads, course pitch) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Applies also with captive washer and hexagon screws with thread cleaning thread. (Metric threads, course pitch) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts. Applies also with captive washer and hexagon screws with thread cleaning thread. (Metric threads, course pitch)
Thread Strength class Strength class
Thread 8.8/8 10.9/10
Thread Tightening Torque (Nm) Tightening Torque (Nm)
M4 2.9 3.6
M5 6 7.5
M6 9.5 12
M8 24 30
M10 47 59
M12 84 105
M12 84 105
M14 135 170
M14 135 170
M16 210 270 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238
M18 290 360 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238
M20 420 530 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238
M22 580 730 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238
M24 730 910 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238
Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts Applies also with captive washer and hexagon screws with thread cleaning thread (Metric Thread, fine interval) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts Applies also with captive washer and hexagon screws with thread cleaning thread (Metric Thread, fine interval) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts Applies also with captive washer and hexagon screws with thread cleaning thread (Metric Thread, fine interval) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts Applies also with captive washer and hexagon screws with thread cleaning thread (Metric Thread, fine interval) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts Applies also with captive washer and hexagon screws with thread cleaning thread (Metric Thread, fine interval) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts Applies also with captive washer and hexagon screws with thread cleaning thread (Metric Thread, fine interval) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts Applies also with captive washer and hexagon screws with thread cleaning thread (Metric Thread, fine interval) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts Applies also with captive washer and hexagon screws with thread cleaning thread (Metric Thread, fine interval) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts Applies also with captive washer and hexagon screws with thread cleaning thread (Metric Thread, fine interval) Hexagonal screws, hexagon socket screws, six-point socket screws, hexagon nuts Applies also with captive washer and hexagon screws with thread cleaning thread (Metric Thread, fine interval)
Thread Thread Tightening torque ( 15 Nm) Thread Tightening torque ( 15 Nm)
Thread 8.8/8 10.9/10
Thread Tightening Torque (Nm) Tightening Torque (Nm)
M8x1 26 32
M10x1.25k 50 62
M12x1.25k 92 115
M14x1.5k 150 180
M16x1.5k 230 290
M18x1.5k 330 410
M20x1.5k 470 590 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238
M22x1.5k 640 800 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238
M24x1.5k 830 1040 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238 FG020238
SP002399 Page 27
Engine
24
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