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Kawasaki 60 z7 wheel loader service repair manual (serial no. 60d1 5001 and up)

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The document is a shop manual section about disassembling and assembling the control valve of a wheel loader. It contains detailed instructions and diagrams for removing and installing the control valve, as well as disassembling and assembling its individual components. The section provides maintenance and repair guidance.

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©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
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
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.
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.
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.
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
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
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
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
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
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).
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
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)
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
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).
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
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
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
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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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
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
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).

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Kawasaki 60 z7 wheel loader service repair manual (serial no. 60d1 5001 and up)

  • 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
  • 20. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
  • 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).