KPS-18T Service Manual ～Disassembly～ 2006.3.
Charge pump NOTE： Use cloths or paper towels to catch and clean up any spilled oil immediately. Remove parts in a clean place. When removing, take care not to enter contamination in cases. When removing O-rings, packing and oil seals, always replace them. Old O-rings, packing and oil seals may be worm or damaged and will result in leaks. Do not remove non-supplied parts. Fig.1 1.KPS-18T Assembly(1) [Fig.1] 2.Remove filter(119) from pump body(100). [Fig.2] 1 3.Remove solenoid cmp(135) from pump body(100).
Charge pump 4.Remove plug(118), spring(117), O-ring(39) and valve(116) from pump body(100). [Fig.5] (Filter bypass valve) Fig.5 116 39 117 118 5.Remove plug(109), spring(110), O-ring(14) and valve(108) from pump body(100). [Fig.6] (Pressure valve) 6.Remove plug(113), spring(114), O-ring(14) and valve(112) from pump body(100). [Fig.6] (Charge relief valve) 7.Remove two bolts(125), cover(123), gasket (124), spring(122), collar(121) and piston (120) from pump body(100). [Fig.7] (Accumlator) Fig.
Charge pump 8.Remove three bolts(45) and two bolts(129). [Fig.8] 45 Fig.8 9.Remove pump body assembly. [Fig.9] 10.Remove O-ring(128), five O-rings(39), two pins (126), two plugs(23), two O-rings(24) and four plugs (105). [Fig.10] 11.Remove inner rotor(103) and outer rotor(104). [Fig.11] *Inspect rotors. Rotors should be free of all nicks and scratches. *Do not drop charge pump rotors(103)(104) and avoid damage of surfaces. *Avoid damage of machined surfaces(center case(3) and pump body(100)). 129 Fig.
Center case 12.Remove key(127) and eight bolts(25). [Fig.12] Fig.12 13.Remove center case assembly, packing(31) and two pins(40) slowly . [Fig.13] X8 127 25 *Remove valve plates(9) from cylinder block cmp (51), when removing center case cmp(2). *Peel off packing that was attached to machined surfaces(center case(3) and housing(27)). *Avoid damage of machined surfaces(center case(3) and housing(27)), when peeling off packing. Center case assembly Fig.13 40 X2 Fig.
Center case 15.Bypass valve cmp(18) CR-valve F cmp(7) CR-valve R cmp(8) [Fig.16] Fig.16 16.Remove two plugs(13), two O-rings(14), spring(12), valves(11), spring(17), valve (16), six plugs(23) and six O-rings(24) from center case (3). [Fig.17] 18 7 Bypass valve cmp 8 CR-valve F cmp CR-valve R cmp Groove for distinction 17.Valve plate(9). [Fig.18] Fig.17 13 14 12 9 X6 24 23 16 11 11 Fig.18 X6 17 14 13 16 *Do not drop valves(11),(16) and valve plates(9).
Cylinder block cmp 18.Remove two cylinder block cmp(51), pipe(36) and two O-rings(34) from housing(27). [Fig.20] Fig.19 19.Cylinder block cmp and piston [Fig.21] 20.Pipe-B cmp(35) [Fig.22] 21.Remove two thrust plates(61), two bolts(63) two nuts(64) and two control arms(62). [Fig.23] *Do not drop pistons when removing cylinder block cmp(51). *Avoid damage of surfaces(pistons(52) and cylinder blocks(55) and thrust plates(61)). *Inspect cylinder blocks(55). Remove and inspect all pistons(52).
Housing(gear , Shaft , Gear 22.Remove plug(38) and O-ring(39) and two plugs (23) and two O-rings(24). And remove fifteen bolts (45). [Fig.24] Fig.24 X15 45 23.Remove housing(43), packing(44)and two pins(40) and remove ring(41), spacer(37) and oil seal(42). [Fig.25] 24 23 24.Remove shaft(input cmp and shaft(pump R cmp shaft(pump L cmp. And pipe(33) and two o-rings (34). [Fig.26] 38 39 *Peel off packing that was attached to machined surfaces(housing(27)(43)).
Shaft, gear 25.Remove two bearings(48), gear(47) from shaft(input(46). [Fig.27] 47 Fig.27 48 X2 46 26.Remove two bearings(57), gear(50) and seal ring(56) from shaft(pump R (58). [Fig.28] 27.Remove two bearings(57), gear(50) and seal ring(56) from shaft(pump L(49). [Fig.29] 28.Remove PTO cmp from housing(27). [Fig.30] Shaft(input cmp Fig.30 PTO cmp 27 *Do not drop gears, shafts and bearings. *Avoid damage of machined surfaces (housing(27), gears, shafts).
PTO cmp 29.Remove bearing(93), spacer(89), PTO gear cmp, clutch cylinder cmp(78), three rods(90) and key(92) from PTO cmp. [Fig.32] Fig.31 30.Remove two bearings(93), ring(87) and gear(77) from PTO gear cmp. [Fig.33] 31.Remove bearing(57), B-plate(96), C-plate(97), three A-plates(95), three friction plates(98), two seal rings (56) and PTO shaft(75). [Fig.33] *Do not drop gear(77), shaft(75) and bearings(57)(93). *Avoid damage of machined surfaces(gear(77), shaft(74)).
Housing(pump , Swash plate 31.Remove friction plate(45) from housing(27). [Fig.34] 32.Remove ring(41), spacer(37), oil seal(42), plugs(29)(38) and O-rings(30)(39) from housing(27). [Fig.36] Fig.34 45 27 33.Remove six bolts(68), two rings(41), two oil seals(42) and two side cover cmp(65) from housing(27). [Fig.37] *If damage is detected, side cover cmp(65) must be replaced. Fig.36 Fig.35 41 37 42 30 29 39 38 Fig.
Housing(pump , Swash plate 34.Remove two swash plates(59) and two washers (60) from housing(27). [Fig.38] Fig.38 60 X2 59 X2 35.Swash plate(59) [Fig.39] 36.Housing(pump cmp(26) [Fig.40] *Do not drop swash plate(59). *Avoid damage of machined surface(housing(27)). 27 Fig.40 26 Fig.
