KPS-18T Service Manual ~Assembly~ 2006.3.
Housing(pump , Swash plate NOTE: Assemble parts on a clean place. When inserting, take care not to enter contamination in cases. When installing, put clean oil on O-rings, lip of oil seals, seal rings and bushings. Fig.2 59 1.Housing(pump cmp(26) [Fig.1] 2.Swash plate(59) [Fig.2] 3.Install two swash plates(59) and two washers(60) into housing(27). [Fig.3] Fig.3 *Put clean oil on contact surfaces of bushings(28). *Avoid damage of machined surface(housing(27)). 28 Fig.
Housing(pump , Swash plate Fig.4 X2 42 X2 41 X6 68 66 28 67 Tightening torque 9.8±1Nm 65 X2 4.Install two side cover cmp(65), six bolts(68), two oil seals(42) and two rings(41) into housing (27). [Fig.4] Fig.5 5.Install plugs(29)(38) and O-rings(30)(39) into housing(27). [Fig.5] 6.Install friction plate(45) onto housing(27). [Fig.7] *If damage is detected, side cover cmp(65) must be replaced. *When installing, take care not to damage lip of oil seal(42). 30 39 29 Tightening torque 24.5±2.
PTO cmp 7.Install bearing(57), three A-plates(95), three friction plates (98), C-plate(97), B-plate(96), two seal rings(56) onto PTO shaft(75). [Fig.9] Fig.8 8.Install two bearings(93) and ring(87) into gear(77). [Fig.9] (PTO gear cmp) 9.Install key(92) onto PTO shaft(75). And install three rods (90), PTO gear cmp into clutch cylinder cmp(78). And install this assembly onto B-plate(96). And install spacer (89) and bearing(93) onto PTO shaft(75). [Fig.
Shaft, gear 10.Install PTO cmp onto housing(27) adjusting forks of friction plates(45). [Fig.11] Fig.11 PTO cmp 27 11.Install two bearings(48) and gear(47) onto shaft(input(46). [Fig.12] (Shaft(input cmp) 12.Install two bearings(57) and gear(50), seal ring(56) onto shaft(pump R(58). [Fig.13] (Shaft(pump R cmp) 13.Install two bearings(57), gear(50), seal ring (56) onto shaft(pump L(49). [Fig.14] (Shaft(pump L cmp) *Avoid damage of machined surfaces (housing(27), gears, shafts).
Housing(gear , Shaft , Gear 14.Install shaft(input cmp, shaft(pump R cmp, shaft(pump L cmp and pipe(A cmp(32) into housing (27). [Fig.15] Fig.15 Shaft(pump L cmp 15.Install two pins(40) into housing(27). And install packing(44) and housing(43) onto housing(27). And install fifteen bolts(45) into housing(43). Tighten screws evenly in a crossing pattern until they are snug. And install oil seal(42) and spacer(37) and ring(41) into housing(43). [Fig.16] Shaft(pump R cmp 33 Shaft(input cmp 34 X2 16.
Cylinder block cmp 17.Install two thrust plates(61) onto swash plates (59). And install oil seal(42), spacer(37) and ring(41) into housing(27). And install two control arms(62), two bolts(63) and two nuts(64) onto swash plates(59). [Fig.18] Fig.18 Piston side 61 Swash plate side X2 61 41 18.Cylinder block cmp and piston [Fig.19] 19.Install two cylinder block cmp(51) onto thrust plates(61). And install pipe(B cmp(36) into housing(27). [Fig.
Center case 20.Install six plugs(23), six O-rings(24), valve(11), spring(12), valve(16), spring(17), two plugs(13), two O-rings(14) into center case(3). [Fig.22] *Put clean oil on the contact surfaces of valves(11)(16). *Avoid damage of surfaces(center case(3) and valve plates(9)). 21.Valve plate(9). [Fig.23] 22.Bypass valve cmp(18) CR-valve F cmp(7) CR-valve R cmp(8) [Fig.24] Fig.22 X6 X6 Tightening torque 24 23 19.6±1.9Nm Tightening torque 24.5±2.5Nm Tightening torque 24.5±2.
Center case 23.Install two valve plates(9) onto center case(3). And install two bypass valve cmp(31), two CR-valve F cmp(7), two CR-valve R cmp(8) into center case(3). [Fig.25] X2 Fig.25 9 Tightening torque 8±1Nm 3 18 X2 24.Center case assembly [Fig.26] 25.Install two pins(40) into housing (27). And install packing(31) and center case assembly onto housing (27). [Fig.27] Fig.27 Tightening torque 34.3±3Nm Tightening torque 34.3±3Nm 8 7 Tightening torque 7 34.
Charge pump 27.Install inner rotor(103) and outer rotor(104) onto center case(3). [Fig.29] Fig.29 104 103 102 3 28.Install two plugs(23), two O-rings(24), O-ring (128), five O-rings(39) and two pins(126) into pump body(100). And install four plugs(105) with seal tape into pump body(100). [Fig.30] 29.Install pump body assembly onto center case(3). [Fig.31] 30.Install three bolts(45) and two bolts(129) into pump body(100). [Fig.32] *Put clean oil on all surfaces of charge pump rotors (103)(104).
Charge pump Fig.33 take care of the direction. 120 31.Install piston(120), spring(122), collar(121) into pump body(100). And install gasket(124) and cover(123) onto pump body(100). And install two bolts(125) into pump body(100). [Fig.33] (Accumlator) 122 121 Tightening torque 24.5±2.5Nm 124 125 X2 123 Tightening torque 24.5±2.5Nm Fig.34 108 32.Install valve(112), spring(114), plug(113) and O-ring(14) into pump body(100). [Fig.
Solenoid cmp , Complete of assembly 35.Install spring(134), sleeve(132) and spool (133) into pump body(100). [Fig.36, Fig.37] 36.Install solenoid cmp(135) into pump body (100). [Fig.36, Fig.37] Fig.36 138 Tightening torque 6.86±0.98Nm 135 141 37.Install filter(119) into pump body(100). [Fig.38] 131 133 139 38.KPS-18T Assembly(1) [Fig.39] Tightening torque 21.6±0.98Nm 132 140 134 *Put clean oil on the contact surfaces of sleeve (132) and spool(133).