service repair manual

1. ©2015 KCM Corporation. All rights reserved. Printed in Japan (K)
( アメリカ用 )
93206-00320
May 2015
SHOP MANUAL
WHEEL LOADER
60Z7
Disassembly & Reassembly
Powered by DEUTZ TCD36 Engine
Serial No. 60D1-5001 and up
60Z7
SHOP
MANUAL
Disassembly
&
Reassembly
93206-00320

2. 93206-00320
May 2015
60Z7 D&R
WORK SHOP MANUAL
SECTION 1 GENERAL INFORMATION
Group 1 Precautions for Disassembling and Assembling.......................................................W1-1
Group 2 Tightening..................................................................................................................W1-2
Group 3 Painting .....................................................................................................................W1-3
Group 4 Bleeding Air...............................................................................................................W1-4
Group 5 Releasing Pressure...................................................................................................W1-5
Group 6 Preparation................................................................................................................W1-6
SECTION 2 MAINTENANCE STANDARD
Group 1 Body ..........................................................................................................................W2-1
Group 2 Travel System ...........................................................................................................W2-2
Group 3 Front Attachment.......................................................................................................W2-3
SECTION 3 BODY
Group 1 Cab............................................................................................................................W3-1
Group 2 Counterweight...........................................................................................................W3-2
Group 3 Center Hinge.............................................................................................................W3-3
Group 4 Engine .......................................................................................................................W3-4
Group 5 Radiator Assembly ....................................................................................................W3-5
Group 6 Hydraulic Oil Tank .....................................................................................................W3-6
Group 7 Pump Device.............................................................................................................W3-7
Group 8 Control Valve.............................................................................................................W3-8
Group 9 Priority Valve .............................................................................................................W3-9
Group 10 Ride Control Device................................................................................................W3-10

3. 60Z7 D&R
SECTION 4 TRAVEL SYSTEM
Group 1 Tire ............................................................................................................................W4-1
Group 2 HST Motor.................................................................................................................W4-2
Group 3 Transmission.............................................................................................................W4-3
Group 4 Axle ...........................................................................................................................W4-4
Group 5 Propeller Shaft ..........................................................................................................W4-5
Group 6 Brake Valve ...............................................................................................................W4-6
Group 7 Steering Device.........................................................................................................W4-7
SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment.......................................................................................................W5-1
Group 2 Cylinder .....................................................................................................................W5-2
All information, illustrations and specifications in this manual are based on the latest product information available at the
time of publication. The right is reserved to make changes at any time without notice.

4. 93206-00300
March 2015
60Z7
SHOP MANUAL (Function & Structure)
INTRODUCTION.......................................................................................................................................IN-01~02
Symbol and Abbreviation...........................................................................................................................SY-1~2
SECTION 1 GENERAL
Group 1 Specifications.................................................................................................................................................T1-1-1
Group 2 Component Layout......................................................................................................................................T1-2-1
Group 3 Component Specifications .......................................................................................................................T1-3-1
SECTION 2 SYSTEM
Group 1 Controller.........................................................................................................................................................T2-1-1
Group 2 Control System..............................................................................................................................................T2-2-1
Group 3 ECM System....................................................................................................................................................T2-3-1
Group 4 Hydraulic System..........................................................................................................................................T2-4-1
Group 5 Electrical System...........................................................................................................................................T2-5-1
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device..................................................................................................................................................T3-1-1
Group 2 Control Valve..................................................................................................................................................T3-2-1
Group 3 Priority Valve...................................................................................................................................................T3-3-1
Group 4 Steering Valve................................................................................................................................................T3-4-1
Group 5 HST Motor .......................................................................................................................................................T3-5-1
Group 6 Transmission...................................................................................................................................................T3-6-1
Group 7 Axle....................................................................................................................................................................T3-7-1
Group 8 Brake Valve......................................................................................................................................................T3-8-1
Group 9 Others...............................................................................................................................................................T3-9-1
Group 10 Ride Control Valve......................................................................................................................................T3-10-1
Group 11 Pilot Valve......................................................................................................................................................T3-11-1
DIAGRAMS
Electrical Connection Diagram
Wiring Diagrams
Hydraulic Circuit Diagram
All information, illustrations and specifications in this manual are based on the latest product information available at the time of
publication. The right is reserved to make changes at any time without notice.

5. 93206-00310
May 2015
60Z7
SHOP MANUAL
(Operational Performance Test & Troubleshooting)
INTRODUCTION........................................................................................................................... IN-01~02
Symbol and Abbreviation...............................................................................................................SY-1~2
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction .............................................................................................................T4-1-1
Group 2 Standard..................................................................................................................T4-2-1
Group 3 Engine Test .............................................................................................................T4-3-1
Group 4 Machine Performance Test .....................................................................................T4-4-1
Group 5 Component Test......................................................................................................T4-5-1
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure ............................................................................................T5-1-1
Group 2 Monitor ....................................................................................................................T5-2-1
Group 3 e-Service .................................................................................................................T5-3-1
Group 4 Component Layout..................................................................................................T5-4-1
Group 5 Troubleshooting A ...................................................................................................T5-5-1
Group 6 Troubleshooting B...................................................................................................T5-6-1
Group 7 Troubleshooting C...................................................................................................T5-7-1
Group 8 Air Conditioner ........................................................................................................T5-8-1
All information, illustrations and specifications in this manual are based on the latest product information available at the
time of publication. The right is reserved to make changes at any time without notice.

6. SECTION 3 BODY
W3-8-1-1
Group 8 Control Valve
Removal and Installation of Control Valve (Manual Type)
IMPORTANT: The hose and pipe contain hydraulic oil.
When removing the hose and pipe, receive oil with
a container in order to avoid spilling oil.
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition,
attach identification tags onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.
Removal
1. Set the machine position (lift arm raise) for
inspection and maintenance. (Refer to W1-6-1.)
CAUTION: Bleed air from the hydraulic oil tank.
(Refer to W1-4-1.)
CAUTION: Release any pressure in the front
attachment hydraulic circuit. (Refer to W1-5-1.)
2. Remove bolts, washers (1) (4 used). Remove cover
(2).
: 17 mm (0.67 in)
3. Disconnect connector (11).
4. Disconnect hoses (10) (4 used).
: 41 mm (1.61 in)
5. Disconnect hose (9) (only the machine with the ride
control device).
: 27 mm (1.06 in)
6. Remove bolt, washer (4), washer (5), nut (6), clip (7),
and clamp (3).
: 17 mm (0.67 in)
7. Disconnect the both ends of pipes (8) (2 used).
: 36 mm (1.42 in)
2
1
WNCC-03-08-001
8
9
10
10
3 4, 5, 6
11
7
WNCC-03-08-002

7. Group 8 Control Valve
SECTION 3 BODY
W3-8-1-1
8. Remove snap pins (7) (2 used), clevis pins (6) (2
used), and washers (8) (2 used). Remove control
cables (1) (2 used).
CAUTION: Control valve (2) weight: 21 kg (47 lb)
9. Attach nylon slings onto control valve (2). Hoist and
hold control valve (2).
10. Remove bolts (3) (3 used), washers (4) (3 used), and
nuts (5) (3 used). Remove control valve (2).
: 19 mm (0.75 in)
11. Remove the adapters with control valve (2) attached
if necessary.
Detail A
A 1 5
4
3
2
WNCC-03-08-003 WNCC-03-08-004
WNCC-03-08-005
7
6
8

8. Group 8 Control Valve
SECTION 3 BODY
W3-8-1-1
Installation
1. Install all removed adapters to control valve (2).
CAUTION: Control valve (2) weight: 21 kg (47 lb)
2. Attach nylon slings onto control valve (2). Hoist
control valve (2).
3. Install control valve (2) with bolts (3) (3 used),
washers (4) (3 used), and nuts (5) (3 used).
: 19 mm (0.75 in)
: 90 N·m (9 kgf·m, 66 lbf·ft)
4. Install control cables (1) (2 used) with clevis pins (6)
(2 used), washers (8) (2 used), and snap pins (7) (2
used).
Detail A
A 1
5
4
2
WNCC-03-08-003
WNCC-03-08-004
WNCC-03-08-005
7
6
8
3

9. Group 8 Control Valve
SECTION 3 BODY
W3-8-1-1
5. Temporarily install the both ends of pipes (8) (2
used), clamp (3), clip (7), and bolt, washer (4),
washer (5), and nut (6).
6. Tighten the both ends of pipes (8) (2 used).
: 36 mm (1.42 in)
: 180 N·m (18 kgf·m, 135 lbf·ft)
7. Tighten bolt, washer (4) and nut (6).
: 17 mm (0.67 in)
: 50 N·m (5 kgf·m, 37 lbf·ft)
8. Connect hose (9) (only the machine with the ride
control device).
: 27 mm (1.06 in)
: 80 N·m (8 kgf·m, 59 lbf·ft)
9. Connect hoses (10) (4 used).
: 41 mm (1.61 in)
: 210 N·m (21 kgf·m, 155 lbf·ft)
10. Connect connector (11).
11. Lower the lift arm. Set the machine position for
inspection and maintenance. (Refer to W1-6-1.)
12. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
13. Set the machine position (lift arm raise) for
inspection and maintenance. (Refer to W1-6-1.)
14. Install cover (2) with bolts, washers (1) (4 used).
: 17 mm (0.67 in)
: 50 N·m (5 kgf·m, 37 lbf·ft)
2
1
WNCC-03-08-001
8
9
10
10
3 4, 5, 6
11
7
WNCC-03-08-002

10. Group 8 Control Valve
SECTION 3 BODY
W3-8-2-5
Disassembly of Control Valve (Manual Type)
1 - Nut (2 Used)
2 - Nut (4 Used)
3 - Support
4 - Lift Arm Spool
Assembly
5 - Bucket Spool Assembly
6 - Overload Relief Valve
7 - O-Ring
8 - Main Relief Valve
9 - O-Ring
10 - Inlet Housing
11 - Rod
12 - Rod (2 Used)
13 - O-Ring (3 Used)
WNCC-03-08-006
3
13
1
2 4
13
5
7
6
9
8
11
1
12
2
12
10
13

11. Group 8 Control Valve
SECTION 3 BODY
W3-8-2-6
Disassembly of Control Valve
IMPORTANT: Attach a spanner onto the hexagonal
part of the relief valve case.
IMPORTANT: Do not disassemble main relief valve
(8).
1. Remove main relief valve (8) from inlet housing (10).
Remove O-ring (9) from main relief valve (8).
: 32 mm (1.26 in)
IMPORTANT: Attach a spanner onto the hexagonal
part of the relief valve case.
IMPORTANT: Do not disassemble overload relief
valve (6).
2. Remove overload relief valve (6) from bucket spool
assembly (5). Remove O-ring (7) from overload relief
valve (6).
: 32 mm (1.26 in)
3. Remove nuts (2) (4 used) from rods (12) (2 used).
Remove nuts (1) (2 used) from rod (11). Remove
rods (12) (2 used) and rod (11) from inlet housing
(10), bucket spool assembly (5), lift arm spool
assembly (4), and support (3).
Nut (1)
: 17 mm (0.67 in)
Nut (2)
: 19 mm (0.75 in)
4. Remove O-rings (13) (3 used) from lift arm spool
assembly (4), bucket spool assembly (5), and inlet
housing (10).

12. Group 8 Control Valve
SECTION 3 BODY
W3-8-2-7
Assembly of Control Valve (Manual Type)
1 - Nut (2 Used)
2 - Nut (4 Used)
3 - Support
4 - Lift Arm Spool
Assembly
5 - Bucket Spool Assembly
6 - Overload Relief Valve
7 - O-Ring
8 - Main Relief Valve
9 - O-Ring
10 - Inlet Housing
11 - Rod
12 - Rod (2 Used)
13 - O-Ring (3 Used)
3
13
1
2 4
13
5
7
6
9
8
11
1
12
2
12
10
13
WNCC-03-08-006

13. Group 8 Control Valve
SECTION 3 BODY
W3-8-2-8
Assembly of Control Valve
IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing.
NOTE: Assemble bucket spool assembly (5) and lift arm
spool assembly (4) beforehand. (Refer to W3-8-3, W3-8-
4.)
1. Install O-rings (13) (3 used) to lift arm spool
assembly (4), bucket spool assembly (5), and inlet
housing (10).
2. Install rods (12) (2 used) and rod (11) to inlet
housing (10), bucket spool assembly (5), lift arm
spool assembly (4), and support (3).
3. Install nuts (2) (4 used) and nuts (1) (2 used) to rods
(12) (2 used) and rod (11).
Nut (1)
: 19 mm (0.75 in)
: 101 N·m (10 kgf·m, 74 lbf·ft)
Nut (2)
: 17 mm (0.67 in)
: 65 N·m (6.5 kgf·m, 48 lbf·ft)
IMPORTANT: Attach a spanner onto the hexagonal
part of the relief valve case.
4. Install O-ring (7) to overload relief valve (6). Install
overload relief valve (6) to bucket spool assembly
(5).
: 32 mm (1.26 in)
: 78 to 88 N·m (7.8 to 8.8 kgf·m 58 to 65 lbf·ft)
IMPORTANT: Attach a spanner onto the hexagonal
part of the relief valve case.
5. Install O-ring (9) to main relief valve (8). Install main
relief valve (8) to inlet housing (10).
: 32 mm (1.26 in)
: 78 to 88 N·m (7.8 to 8.8 kgf·m, 58 to 65
lbf·ft)

14. Group 8 Control Valve
SECTION 3 BODY
W3-8-3-9
Disassembly of Bucket Spool Assembly (Manual Type)
1 - Housing
2 - Spool
3 - Poppet
4 - Spring
6 - Seal Ring (2 Used)
7 - Wiper Ring (2 Used)
8 - Screw (2 Used)
9 - Seal Plate (2 Used)
10 - Pin
11 - Spring Seat (2 Used)
12 - Spring
13 - Cap
14 - Plate
15 - Socket Bolt
16 - Nut
17 - Coil Tube
18 - Socket Bolt (2 Used)
19 - Nut
WNCC-03-08-007
9
7
6
1
8
3
4
6
7
9
2
11
12
11
18
13
19
10
16
14
15
17

15. Group 8 Control Valve
SECTION 3 BODY
W3-8-3-10
Disassembly of Bucket Spool Assembly
1. Remove spring (4) and poppet (3) from housing (1).
2. Attach copper plates onto the vise. Secure the
housing (1) assembly.
3. Loosen nut (19). Remove coil tube (17) from cap
(13).
Coil Tube (17)
: 41 mm (1.61 in)
Nut (19)
: 41 mm (1.61 in)
NOTE: LOCTITE #242 has been applied on the thread
part of cap (13).
4. Remove socket bolts (18) (2 used). Remove the
spool (2) assembly and seal plate (9) from housing
(1).
: 5 mm (0.2 in)
NOTE: The spool (2) assembly can be removed easily
from housing (1) by turning spool (2).
5. Remove screws (8) (2 used). Remove seal plate (9)
from housing (1).
6. Remove wiper rings (7) (2 used) and seal rings (6) (2
used) from housing (1).
7. Attach copper plates onto the vise. Secure the spool
(2) assembly.
8. Loosen nut (16). Remove socket bolt (15) and plate
(14) from pin (10). Remove nut (16) from socket bolt
(15).
Socket Bolt (15)
: 4 mm (0.16 in)
Nut (16)
: 8 mm (0.31 in)
NOTE: LOCTITE #271 has been applied on the thread
part of socket bolt (15).
IMPORTANT: Attach a spanner onto the hexagonal
part of pin (10).
9. Remove pin (10), spring seats (11) (2 used), spring
(12), and cap (13) from spool (2).
: 17 mm (0.67 in)
NOTE: LOCTITE #271 has been applied on the thread
part of pin (10).

16. Group 8 Control Valve
SECTION 3 BODY
W3-8-3-11
Assembly of Bucket Spool Assembly (Manual Type)
1 - Housing
2 - Spool
3 - Poppet
4 - Spring
6 - Seal Ring (2 Used)
7 - Wiper Ring (2 Used)
8 - Screw (2 Used)
9 - Seal Plate (2 Used)
10 - Pin
11 - Spring Seat (2 Used)
12 - Spring
13 - Cap
14 - Plate
15 - Socket Bolt
16 - Nut
17 - Coil Tube
18 - Socket Bolt (2 Used)
19 - Nut
WNCC-03-08-012
3
4
1
17
15
14
16
10
19
13
18
2
9 11 12 11
6
7
9
8

17. Group 8 Control Valve
SECTION 3 BODY
W3-8-3-12
Assembly of Bucket Spool Assembly
IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing.
1. Attach copper plates onto the vise. Secure spool (2).
2. Apply LOCTITE #271 onto the thread part of pin (10).
Install spring seats (11) (2 used) and spring (12) to
spool (2) with pin (10).
: 17 mm (0.67 in)
: 14.7 to 19.6 N·m (1.5 to 2 kgf·m 11 to 14.5
lbf·ft)
3. Install cap (13) to spool (2).
5. Attach copper plates onto the vise. Secure housing
(1).
IMPORTANT: Check the direction to install seal
rings (6) (2 used) and wiper rings (7) (2 used).
6. Install seal rings (6) (2 used) and wiper rings (7) (2
used) to housing (1). Install seal plate (9) to housing
(1) with screws (8) (2 used).
: 2.5 to 2.9 N·m (0.3 kgf·m, 1.8 to 2.1 lbf·ft)
7. Install seal plate (9) and the spool (2) assembly to
housing (1).
NOTE: The spool (2) assembly can be installed easily to
housing (1) by turning spool (2).
8. Install cap (13) to housing (1) with socket bolts (18)
(2 used).
: 5 mm (1.2 in)
: 8.8 to 9.8 N·m (0.9 to 1 kgf·m, 6.5 to 7.2
lbf·ft)
9. Apply LOCTITE #242 onto the thread part of cap
(13). Turn and install coil tube (17) to cap (13) until
they come in contact with plate (14). Move back coil
tube (17) by a 1/4 turn (approx. 0.3 mm (0.012 in))
from the position where it has come in contact with
plate (14). Secure coil tube (17) with nut (19).
Coil Tube (17)
: 41 mm (1.61 in)
Nut (19)
: 41 mm (1.61 in)
: 60.8 N·m (6.1 kgf·m, 45 lbf·ft)
10. Remove the housing (1) assembly from the vise.
11. Install poppet (3) and spring (4) to the housing (1)
assembly.
4. Apply LOCTITE #271 onto the thread part of socket
bolt (15). Install plate (14) to pin (10) with nut (16)
and socket bolt (15) by using a thickness gauge so
that dimension (a) should be 0.5 mm. (0.02 in)
Socket Bolt (15)
: 4 mm (0.16 in)
Nut (16)
: 8 mm (0.31 in)
: 2 to 3.2 N·m (0.2 to 0.3 kgf·m, 1.5 to 2.4
lbf·ft)
W4FJ-02-06-008
a- 0.5 mm (0.02 in)
15
14
16
10
a
WNCC-03-08-009
7
6
6
7
1

18. Group 8 Control Valve
SECTION 3 BODY
W3-8-4-13
Disassembly of Lift Arm Spool Assembly (Manual Type)
1 - Housing
2 - Spool
3 - Poppet
4 - Spring
6 - Seal Ring (2 Used)
7 - Wiper Ring (2 Used)
8 - Screw (2 Used)
9 - Seal Plate (2 Used)
10 - Pin
11 - Sleeve
12 - Spring
13 - Spring
14 - Spring Seat (2 Used)
15 - Steel Ball
16 - Steel Ball (4 Used)
17 - Cap
18 - Spacer
19 - O-Ring
20 - Spacer
21 - Retaining Ring
22 - Socket Bolt (2 Used)
23 - Shim
9
7
6
1
8
3
4
19
18
6
2
14
10
23
12
15
16
22
17
11
20
21
14
13
7
9
WNCC-03-08-008

19. Group 8 Control Valve
SECTION 3 BODY
W3-8-4-14
Disassembly of Lift Arm Spool Assembly
1. Remove spring (4) and poppet (3) from housing (1).
2. Attach copper plates onto the vise. Secure the
housing (1) assembly.
3. Remove socket bolts (22) (2 used). Remove the
spool (2) assembly from housing (1).
: 5 mm (0.2 in)
NOTE: The spool (2) assembly can be removed easily
from housing (1) by turning spool (2).
4. Remove screws (8) (2 used). Remove seal plate (9)
from housing (1).
5. Remove wiper ring (7) and seal ring (6) from
housing (1).
6. Attach copper plates onto the vise. Secure the spool
(2) assembly.
7. Remove retaining ring (21) and spacer (20) from cap
(17).
9. Remove steel balls (16) (4 used), steel ball (15),
spring (12), and shim (23) from pin (10).
10. Install round bar (a) (6 mm (0.24 in) or less) to
the steel ball (16) hole of pin (10). Slowly turn
pin (10) counterclockwise and release spring (13)
compression force.
NOTE: The spring (13) force is applied to pin (10).
NOTE: LOCTITE #271 has been applied on the thread
part of pin (10).
11. Remove pin (10), spring seats (14) (2 used), and
spring (13) from spool (2).
12. Remove seal plate (9) and spacer (18) from spool (2).
13. Remove wiper ring (7), seal ring (6), and O-ring (19)
from spacer (18).
IMPORTANT: Do not lose steel ball (15) and steel
balls (16) (4 used) as they fly out due to the spring
(12) force.
8. While pushing steel ball (15) through the pin (10)
hole by using hexagonal wrench (a) (3 mm (0.12 in)
or less), remove sleeve (11) and cap (17) from the
spool (2) assembly. Remove hexagonal wrench (a).
15 16 a
12
11
17
10
2
a- Hexagonal Wrench
W4FJ-02-06-010
10
13
a
a- Round Bar W4FJ-02-06-009

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your reading. Please Click
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21. Group 8 Control Valve
SECTION 3 BODY
W3-8-4-15
Assembly of Lift Arm Spool Assembly (Manual Type)
1 - Housing
2 - Spool
3 - Poppet
4 - Spring
6 - Seal Ring (2 Used)
7 - Wiper Ring (2 Used)
8 - Screw (2 Used)
9 - Seal Plate (2 Used)
10 - Pin
11 - Sleeve
12 - Spring
13 - Spring
14 - Spring Seat (2 Used)
15 - Steel Ball
16 - Steel Ball (4 Used)
17 - Cap
18 - Spacer
19 - O-Ring
20 - Spacer
21 - Retaining Ring
22 - Socket Bolt (2 Used)
23 - Shim
1
21
20
11
10
22
17
9
18
2
14 12 16 15
6
7
9
8
WNCC-03-08-013
23
13
14
7
6
19
3
4

22. Group 8 Control Valve
SECTION 3 BODY
W3-8-4-16
Assembly of Lift Arm Spool Assembly
IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing.
1. Attach copper plates onto the vise. Secure spool (2).
IMPORTANT: Check the direction to install seal ring
(6) and wiper ring (7).
2. Install seal ring (6), wiper ring (7), and O-ring (19) to
spacer (18).
3. Install spacer (18) and seal plate (9) to spool (2).
4. Apply LOCTITE #271 onto the thread part of pin (10).
Install pin (10), spring seats (14) (2 used), and spring
(13) to the spool (2) assembly.
5. Install a round bar (6 mm (0.24 in) or less) to the
steel ball (16) hole of pin (10). Slowly turn pin (10)
clockwise and compress spring (13).
: 14.7 to 19.6 N·m (1.5 to 2 kgf·m, 11 to 14.5
lbf·ft)
NOTE: The spring (13) force is applied to pin (10).
IMPORTANT: Do not lose steel ball (15) and steel
balls (16) (4 used) as they fly out due to the spring
(12) force.
6. Apply grease onto the pin (10) hole. Install shim
(23), spring (12), steel ball (15), and steel balls (16) (4
used) to the pin (10) hole.
7. While pushing steel ball (15) through the pin (10)
hole by using hexagonal wrench (a) (3 mm (0.12 in)
or less), install sleeve (11) and cap (17) to the spool
(2) assembly. Remove hexagonal wrench (a).
8. Install spacer (20) and retaining ring (21) to cap (17).
9. Attach copper plates onto the vise. Secure housing
(1).
IMPORTANT: Check the direction to install seal ring
(6) and wiper ring (7).
10. Install seal ring (6) and wiper ring (7) to housing (1).
11. Install seal plate (9) to housing (1) with screws (8) (2
used).
: 2.5 to 2.9 N·m (0.3 kgf·m, 1.8 to 2.1 lbf·ft)
WNCC-03-08-010
7
6
18
19
16 a
15
12
11
17
10
2
W4FJ-02-06-010
6
7
1
WNCC-03-08-011
a- Hexagonal Wrench

23. Group 8 Control Valve
SECTION 3 BODY
W3-8-4-17
12. Install the spool (2) assembly to housing (1) with
socket bolts (22) (2 used).
: 5 mm (0.2 in)
: 8.8 to 9.8 N·m (0.9 to 1 kgf·m, 6.5 to 7.2
lbf·ft)
NOTE: The spool (2) assembly can be installed easily to
housing (1) by turning spool (2).
13. Remove the housing (1) assembly from the vise.
14. Install poppet (3) and spring (4) to housing (1).