Husqvarna Tuff Torq K61 Service Manual Download Page 48

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Troubleshooting and Diagnosis Guides

P O S S I B L E C A U S E

P O S S I B L E S O L U T I O N

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ACCUMULATION OF GRASS AND/OR OTHER DEBRIS
INTERFERENCE

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BY-PASS (TOW) VALVE CONTROL LINKAGE BENT, BRO-
KEN, DISCONNECTED, OR BINDING

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BY-PASS (TOW) VALVE PARTIALLY ACTIVATED

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BY-PASS (TOW) VALVE ACTIVATED

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BY-PASS (TOW) ORIFICE LOCATED IN WRONG PORT

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BINDING, BROKEN, OR MISSING INTERNAL COMPO-
NENTS (PUSH PIN, SPRING, POPPETS, ETC) OR INTER-
NAL LEAKAGE IN BY-PASS (TOW) VALVE

By-Pass (Tow) Valve Does Not Operate Correctly

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CLEAN TRANSAXLE/TRACTOR OF ACCUMULATED
DEBRIS

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REPAIR OR REPLACE DAMAGED COMPONENTS - AD-
JUST FOR PROPER OPERATION

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CHECK BY-PASS (TOW) VALVE CONTROL FOR BENT,
BROKEN, DISCONNECTED OR BINDING LINKAGE

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CHECK BY-PASS (TOW) VALVE CONTROL FOR BENT,
BROKEN, DISCONNECTED OR BINDING LINKAGE

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CORRECT LOCATION IS INDICATED BY CREEP OF
TRACTOR’S WHEEL WHEN PUSHED FORWARD AND
LOCKED UP WHEN TRACTOR IS PUSHED REARWARD

CENTER CASE REPLACEMENT REQUIRED

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TRANSAXLE REPAIR REQUIRED

Summary of Contents for Tuff Torq K61

Page 1: ......

Page 2: ...Final Pinon Assembly 4 Final Pinon Assembly Removal 4 Fulcrum Removal 14 Hydraulic Flow Diagram 17 Hydrostatic Pump Removal 9 Levers Shafts and Linkage Removal 16 Lower Case Removal 3 Magnet Removal 9 Motor Housing Removal 10 Motor Shaft Removal 11 Pump Shaft Removal 15 Shock Absorber and Control Arms Removal 2 Swash Plate Removal 13 Assembly of Transaxle 18 Adjusting Neutral 36 Axle Shafts and Di...

Page 3: ...athead Screw Driver 10 Roll Pin Punch 11 Feeler Gauge 12 Calipers 13 Putty Knife 14 Wrench size 8 millimeter 12 millimeter 14 millimeter 17 millimeter 15 Sealant 16 Grease 17 Filter 18 Seal Kit s 19 Oil 10W 30 Class CC or CD Speciﬁcations Transaxle Torque output 217 Ft lbs Maximum Input Speed 3000 RPM Input Shaft Size 14 85 mm 0 58 in Reduction Ratio 18 79 1 or 26 97 1 Axle Shaft Size 25 4 mm 1 0 ...

Page 4: ...l Drain Plug and Pressure Fill Plug removal Always install a new Seal Washer on the Drain Plug and new O rings on Pressure Fill Plug when reas sembling Brake Assembly Removal 1 Remove the Cotter Pin and Washer from the Brake Rod Assembly Fig 2 2 Remove the Brake Rod Assembly from Brake Arm B see Fig 3 by pivoting 90 degrees and sliding downward Fig 2 3 Loosen and remove the 3 8 mm bolts washers 12...

Page 5: ...k Absorber Fig 3 2 Remove the Roll Pin and the H Control Arm from the Control Shaft Fig 4 3 Remove the Roll Pin and the Brake Arm from the Brake Shaft Fig 4 4 Remove the Roll Pin and Brake Arm B from Brake Arm A Fig 4 5 Remove the Roll Pin and the Tow Release Valve Arm from the Bypass Shaft Fig 4 Fig 4 Arms and Roll Pins ...

Page 6: ... and Lower Housing Removal If separation does not occur easily a screw driver can be inserted at any of the 4 pry points indi cated by the black arrows Fig 6 Fig 6 Pry Points Care should be taken not to damage the Hous ing Sealing lips while prying apart Remove any old sealant residue from both case halves Filter Removal 1 Remove the Filter from the Center Case and discard Fig 7 Fig 7 Filter Remov...

Page 7: ... position Separate the assembly Bear ing Bushing Washer Final Pinon Shaft and Reduction Fig 10 11 2 Inspect the Final Pinion Shaft and the Reduction Gear for scoring pitting discoloration and chipped or broken teeth Fig 11 Fig 11 Final Pinion Assembly Carefully inspect all parts for wear or damage Replace as necessary Fig 10 Final Pinon Assembly Removal Bypass Valve Removal Final Pinion Assembly R...

Page 8: ... 0 48 mm of clearance Example of an Unacceptable Tolerance Pinion Shaft O D X 14 75 mm Bushing I D Y 15 29 mm Y 15 29 mm X 14 75 mm 0 54 mm of clearance This is the wear limit of 0 50 mm replacement is necessary Fig 13 Differential Gear Assembly and Axle Removal Final Pinion Shaft and Bushing Tolerances 1 Using calipers digital recommended measure the O D X of the Final Pinion Shaft Fig 12 Fig 12 ...

Page 9: ...Differential Gear Assembly Removal continued 1 Remove Thrust Washer from either the Left or Right Axle Fig 14 16 2 After removing the Thrust Washer rotate the Axle until the open end of C Ring is facing downward Holding the Diﬀerential Side Gear stationary slightly slide the Axle outward exposing the C Ring Using a Telescoping Mag net remove C Ring Fig 14 16 3 Repeat steps 1 and 2 for opposing sha...

Page 10: ... Measure the I D Y of the Loose Bushing Fig 15 3 If the clearance Y X is 0 35 mm 0 014 in replace the Axle Shaft and or loose Bushing Example of an Unacceptable Tolerance Axle Shaft O D X 18 89 mm Bushing I D Y 19 25 mm Y 19 25 mm X 18 89 mm 0 36 mm of clearance This is the wear limit of 0 35 mm replacement is necessary Fig 16 Differential Gear and Axles Axel Shafts and Differential Gear Assemblie...

Page 11: ...ng Seals from the Upper Case Immediately behind each Axle Seal is a press ﬁt bushing If damaged the Upper Case must be replaced bushings can not be replaced separately Seals should be replaced every time the Axles are removed 2 Measure the I D Y of the Pinion Gears Fig 18 3 If the clearance Y X is 0 50 mm 0 019 in replace the Pinion Shaft and or Pinion Gears Example of an Unacceptable Tolerance Pi...

Page 12: ...ly lift the entire assembly from the Upper Case Fig 22 Fig 22 Center Case and Motor Shaft Assemblies Magnet Removal 1 Loosen 3 Bolts 10 mm removing one on the Cen ter Case remove the Magnet Clean the Magnet thor oughly before reassembling Fig 21 Fig 21 Magnet Removal Fig 20 Center Case and Motor Shaft Assemblies Hydrostatic Pump Removal Slide the Brake Drum onto the Motor Shaft to provide a means ...

Page 13: ...achined surfaces Fig 26 Finger placement during removal To avoid the pistons from dropping out during removal of the assembly position ﬁngers around the Cylinder in order to apply pressure on each of the ﬁve pistons Fig 26 Hydrostatic Pump Removal continued Center Case Removal 3 While still maintaining pressure on the Cylinder Block Assembly and the Motor Housing carefully separate the Center Case...

Page 14: ...s ﬁt Bear ing on the Motor Shaft unless it is damaged or worn Motor Housing Removal 6 Remove the Spring and Snap Ring Next remove the Thrust Bearing Set seated in the Motor Housing Fig 27 7 Inspect the press ﬁt Bushing in the Motor Housing for burrs scoring pitting discoloration and wear If dam aged replace the Motor Housing press ﬁt Bushings are not serviced separately 8 Remove the Snap Ring and ...

Page 15: ... the Pistons do not fall out of Cylinder Block Do not set Cylinder Block down with mating surface contacting table top as this also could cause damage To avoid the pistons from dropping out during removal of the assembly position ﬁngers around the Cylinder in order to apply even pressure to all ﬁve pis tons Fig 32 Fig 32 Finger Placement During Removal During separation be careful not to damage co...

Page 16: ...s If the clearance gap is 0 15 mm 0 005 in replace both Shift Blocks and the Swash Plate Assembly simultaneously Fig 34 Fig 34 Shift Blocks ClearanceTolerance 2 Remove the Spring and the Snap Ring Fig 35 Fig 35 Swash Plate Removal 3 Remove the Thrust Bearing seated in the Swash Plate Fig 36 4 Remove the Swash Plate Fig 36 5 Inspect the press ﬁt Bushing in the Swash Plate for burrs scoring pitting ...

Page 17: ...esh pair Fig 41 Fig 41 Fulcrum Swash Plate Removal continued Fig 38 Swash Plate s Machined Ramps Inspect the Swash Plate s machined ramp sur faces and Press Fit Bushings for scoring pitting dis coloration and wear If the Swash Plate and or Bush ings are damaged they must be replaced as a group 7 Using calipers digital recommended measure the thickness of both Thrust Metals for wear If the clear an...

Page 18: ...ing Pump Shaft Removal 1 Remove the Seal and discard Replace with new a Seal during reassembly Fig 42 2 Remove the large internal Snap Ring and lift the Pump Shaft from the Upper Case Fig 43 Inspect the Shaft and its components for scor ing pitting discoloration and other wear Replace if damage or worn Inspect the Pump Shaft splines for chipped or broken teeth Fig 42 Pump Shaft Seal Removal ...

Page 19: ... A Fig 44 6 Disengage the Brake Return Spring from the Brake Shaft and the Upper Case remove the Spring after steps 8 and 9 7 Disengage the Bypass Rod from the slot on the Brake Shaft Remove the Bypass Rod Fig 45 8 Remove the Brake Shaft Fig 45 9 Remove the Bypass Shaft and Spring Fig 45 Remove and discard O rings on Shafts Replace with new O rings before reassembly Refer to the As sembly section ...

Page 20: ...17 Tuff Torq K61 Hydrostatic Transaxle Hydraulic Flow Diagram ...

Page 21: ...l the Spring onto the Bypass Shaft 4 Install the Spring and Bypass Shaft into the hole on the Upper Case Fig 1 Apply a light coating of grease to the surface of the O ring Also apply a small amount of grease into mating hole of Upper Case Fig 1 Bypass Shaft Assembly Rather than lubricating packing items O rings and Seals in advance apply a light coating of grease just prior to their installation T...

Page 22: ...tall a new O ring onto the Brake Shaft Fig 4 2 Check Bushing for damage or exceptionable wear replace if necessary Fig 4 Fig 4 Brake Shaft Assembly Apply a light coating of grease to the surface of the new O ring and Bushing Also apply a small amount of grease into mating hole of the Upper Case 3 Align the Bypass Rod with the slot on the Brake Shaft Fig 5 7 4 Place the Brake Return Spring under th...

Page 23: ... ring onto the Brake Arm Fig 8 2 Attach the Brake Rod to the Brake Arm then to the Brake Shaft Fig 8 9 Apply a light coating of grease to the surface of the new O ring and Bushing Also apply a small amount of grease into mating hole of Upper Case Fig 8 Brake Arm Assembly 3 Secure the Brake Rod to the Brake Shaft with a Washer and Cotter Pin Fig 9 Fig 9 Brake Rod Assembly With the Brake Linkage in ...

Page 24: ...per Case Fig 13 Fulcrum 3 Place the head of the Fulcrum between the legs of the Torsion Spring Fig 14 Fig 14 Fulcrum Control Shaft Assembly 4 Apply an ample amount of grease to the inside surface of the Shift Blocks and to the pivot ball then press the Shift Blocks to the pivot ball The grease will help retain the Shift Blocks in position during installation and align ment of the Swash Plate Assem...

Page 25: ...ever is installed Fig 17 Hydrostatic Control Arm Assembly To avoid possible damage to the splines of the Pump Shaft ﬁrst install all levers and control arms The driving in of the respective Roll Pins could result in the unintentional contact with the shaft If shaft is al ready present place a protective covering over spline e g electrical tape Pump Shaft Assembly 1 Install a new Bearing onto the P...

Page 26: ...Install a new Seal To avoid possible damage to the Seal lip during installation cover the splines of the Pump Shaft with tape Fig 19 Pump Shaft Assembly Apply a light coating of grease to the surface of all Seals and O rings Also apply a small amount of grease around the mating hole of the Upper Case For Bearings and other machined parts apply a coating of oil ...

Page 27: ...e Shift Blocks in position during installation and alignment of the Swash Plate Assembly See Control Shaft and Fulcrum Assembly step 4 on page 21 Fig 20 4 Coat the exposed surfaces of the Thrust Metals with oil 5 Place the Swash Plate Assembly over the Pump Shaft then into cradle align with Shift Blocks Fig 20 Fig 20 Pump Shaft Assembly 6 Using feeler gauge check the distance between the Swash Pla...

Page 28: ...ey must be replaced with a complete Cylinder Block Assembly Individual compo nents are not serviced separately Motor Shaft Assembly 1 Install a new Bearing onto the Motor Shaft if required 2 Lubricate Bearing with clean oil old or new 3 Installation involving a new Bearing Fig 25 Press Bearing into position Install Washer Seat Snap Ring in the Motor Shafts groove 4 Install a new Seal onto the Moto...

Page 29: ...f all Seals and O rings Also apply a small amount of grease around the mating hole of the Upper Case For Bearings and other machined parts apply a coating of oil Fig 26 Motor Shaft Housing Assembly 9 Place the 5 washers springs and pistons into Motor Cylinder Block Fig 27 Fig 27 Motor Cylinder Block 10 Align splines of the Cylinder Block Assembly and the Motor Shaft then press together until pisto...

Page 30: ...ins 2 Push Pin Assemblies 2 Sleeve Assemblies Sleeve Assembly Not Illustrated 2 Pin Holders 2 Ball Springs 2 Ball Holders 2 Balls 2 Back Up Rings Sleeve A1 with oriﬁce Sleeve A2 Fig 29 Center Case Assembly Apply a light coating of oil to the Push Pins Valves Alignment Pins and the Machine surfaces of the Center Case Fig 29 30 Fig 30 Center Case Machined Surfaces If Sleeves are removed it is import...

Page 31: ...pper Case as a single unit Fig 35 This may be the most difﬁcult procedure in the entire assembly of the Transaxle if not the most critical For this assembly to go smoothly several things need to occur simultaneously Pay particular attention to install motor housing in same orientation that it was removed with recesses dimples facing up Incorrect installation will result in improper operation of tr...

Page 32: ...y with Upper Case if Magnet is not correctly located 4 Tighten the 3 10 mm Bolts 14 mm wrench evenly to draw Center Case Assembly into place Tightening torque 4 5 6 5 kg m 44 3 63 9 N m 33 47 ft lbs 5 Install Push Pins Springs and Bypass Valves in Center Case then while depressing Push Pin Assemblies place C Arm onto Bypass Shaft Fig 37 Fig 37 ActuatingValve Assembly Fig 35 Hydrostatic Pump and Mo...

Page 33: ...eft and Right Axle Shafts Fig 39 Apply a light coating of grease to Seal before installation Also apply a small amount of grease to the chamfer of bore Install Seals from internal splined side of Axles to avoid cutting Seal lip on sharp edge of ring groove and keyway However if Axle Shafts are already in place apply tape over ring groove and keyway to pro tect Seal lip 2 Install Left and Right Axl...

Page 34: ... Washers to the Left and Right Axle Shafts Fig 41 Axle Shafts should rotate freely turn by hand to check for ease of rotation Also verify that the C Rings and Thrust Washers are properly seated by pulling out ward on both Axle Shafts There should be very little travel conﬁrming that Axles are secure 7 Press both Axle Shaft Seals squarely into case beyond chamfer of bore Fig 41 Differential Gear In...

Page 35: ...shing onto Final Pinion Shaft Fig 42 3 Install Final Pinion Shaft Assembly into Upper Case Fig 43 Install Bushing with ﬂat surface parallel to the surface of the Upper Case Lower Case will not mate properly with Upper Case if Bushing is improperly in stalled Fig 42 Pinion Gear Assembly Fig 43 Final Pinion Shaft Assembly ...

Page 36: ...rface of Lower Case following along the inside surface of bolt holes Be sure to apply sealant aroung center bolt hole Fig 45 Clean mating surfaces of Transaxle thoroughly before applying sealant Activate the Bypass Linkage so that C Arm Fig 43 retracts providing additional clearance for the position ing of the Lower Case onto the Upper case 3 Position Lower Case onto Upper Case Press together Fig ...

Page 37: ...ng torque 1 3 1 7 kg m 12 8 16 7 N m 113 148 in lbs 7 Install 2 new O rings and the 1 8 plug 5 mm hex wrench onto Connector Pressure Fill Plug Apply grease to surface of O rings If 1 8 inch Pressure Plug was removed ap ply Teﬂon tape to threads of plug before reinstalling Fig 47 8 Install Connector through Lower Case s opening into Center Case port Fig 47 Oil Plug Connector Install Before installi...

Page 38: ... the Engagement Lever tighten using a 12 mm wrench the 3 Bolts Tightening torque 2 3 3 0 kg m 22 6 29 5 N m 17 21 ft lbs 4 Attach the Brake Rod Assembly to the Brake Arm 5 Adjust the Brake Rod to align with the Engagement Lever and connect 6 Connect the Washer and Cotter Pin 7 Conﬁrm that the Band Brake is properly aligned and working smoothly 8 If Applicable Connect one end of the Shock Absorber ...

Page 39: ...ce from the forward stop point Fig 51 11 Hold the Fulcrum Shaft with a 8 mm wrench and tighten the 17 mm Lock Nut Fig 51 Fig 51 Neutral Adjustment 1 12 Conﬁrm no rotation of the Axle Shaft in neutral by slow ly returning the Control Lever to neutral from forward and reverse Post Assembly Procedures 1 Pour new SAE 10W30 Class CC or CD engine oil approx 2 5 L 2 65 qt into the Transaxle until oil lev...

Page 40: ...axle will outlast the life of the vehicle It must be said that changing oil will extend the life of the transmission However in commercial and heavy usage applications oil changing is recommended after the ﬁrst 50 hours of operation and every 200 hours thereafter The ﬁlter should never require changing unless the transaxle is removed from the tractor or riding mower and opened for repairs Oil Requ...

Page 41: ...D DIF FERENTIAL ASSEMBLY Note If your speciﬁc problem and or solution is not listed below consult a qualiﬁed Tuff Torq Distributor CLEAN TRANSAXLE TRACTOR OF ACCUMULATED DEBRIS CHECK OIL LEVEL IN EXPANSION TANK SAE 10W30 MOTOR OIL BRAKE LINKAGE BROKEN BENT BINDING OR OUT OF ADJUSTMENT MAKE NECESSARY CORRECTIONS AD JUSTMENTS MAKE NECESSARY CORRECTIONS ADJUSTMENTS INSPECT FAN FOR DAMAGE CHECK FOR FA...

Page 42: ... SETTING OUT OF ADJUSTMENT INTERNAL DAMAGE TO SHIFT CONTROL SHAFT SWASH PLATE AND COMPONENTS THRUST METALS BEARING PADS AND NEUTRAL RETURN SPRING CLEAN AND INSPECT TRANSAXLE FOR ACCUMULAT ED DEBRIS AND WORN LINKAGE COMPONENTS SEE PROCEDURE FOR PROPER ADJUSTMENT CLEAN BRAKE COMPONENTS WITH BRAKE CLEANER Brakes Malfunction INSPECT FAN PULLEY FOR DAMAGE CHECK MOUNT ING HARDWARE MAKE NECESSARY CORRECT...

Page 43: ... PLUG TO 2 0 2 5 KG M 15 18 FT LBS CHECK OIL LEVEL RESEAL AND TORQUE BOLTS TO 2 3 2 8 KG M 17 20 6 FT LBS Hard Shifting SPEED SHIFT CONTROL LINKAGE BELT BINDING AND OR WORN INCORRECT OIL OIL LEVEL IN TRANSAXLE SHOCK ABSORBER DAMPER BENT RUSTY WORN OR MISSING INTERNAL DAMAGE TO SHIFT CONTROL SHAFT SWASH PLATE AND COMPONENTS THRUST METALS BEARING PADS AND NEUTRAL RETURN SPRING Oil Leakage EXCESSIVE ...

Page 44: ... OF ADJUSTMENT WORN FRAYED OR MISSING SPEED SHIFT CONTROL SHAFT ROLL PIN SHEARED OR MISSING ON TRANSAXLE PARKING BRAKE ENGAGED SPEED SHIFT CONTROL LINKAGE BROKEN BENT DISCONNECTED OR BINDING ENGINE OR TRANSAXLE PULLEY TURNING ON AT TACHED SHAFT REPLACE SEALS AND O RINGS AS REQUIRED INSPECT DRIVE BELT REPLACE AND OR ADJUST PER PROPER PROCEDURE INSPECT IDLER PULLEY COMPONENTS MAKE NECES SARY CORRECT...

Page 45: ... CONNECTOR NOT OIL PLUG LOOSE AT BOTTOM OF CASE INTERNAL BINDING DAMAGE TO SHIFT CONTROL SHAFT SWASH PLATE AND COMPONENTS THRUST METALS BEARING PADS ROTATING GROUPS OR CENTER CASE CHECK BY PASS TOW VALVE CONTROL FOR BENT BROKEN DISCONNECTED OR BINDING LINKAGE TRANSAXLE REPLACEMENT OR REPAIR REQUIRED CLEAN TRANSAXLE TRACTOR OF ACCUMULATED DEBRIS REPAIR OR REPLACE DAMAGED COMPONENTS AD JUST SHIFT LI...

Page 46: ...RIVE BELT REPLACE AND OR ADJUST PER PROPER PROCEDURE SEE TRANSMISSION OVERHEATING PROBLEM BRAKE LINKAGE BROKEN BENT BINDING OR OUT OF ADJUSTMENT MAKE NECESSARY CORRECTIONS AD JUSTMENTS REDUCE LOAD ALLOW TRANSAXLE TO COOL REPAIR ENGINE TRANSAXLE REPLACEMENT OR REPAIR REQUIRED CHECK KEYS FOR PROPER INSTALLATION MAKE NECESSARY CORRECTIONS ADJUSTMENTS CLEAN TRANSAXLE TRACTOR OF ACCUMULATED DEBRIS CHEC...

Page 47: ...Y PASS VALVE COMPONENTS OR DIFFERENTIAL ASSEMBLY Lower Power Both Directions continued CHECK BY PASS TOW VALVE CONTROL FOR BENT BROKEN DISCONNECTED OR BINDING LINKAGE TRANSAXLE REPLACEMENT OR REPAIR REQUIRED FILTER REPLACEMENT REQUIRED CHECK KEYS FOR PROPER INSTALLATION AND MAKE NECESSARY CORRECTIONS ADJUSTMENTS CLEAN TRANSAXLE TRACTOR OF ACCUMULATED DEBRIS CHECK OIL LEVEL IN EXPANSION TANK SAE 10...

Page 48: ...NENTS PUSH PIN SPRING POPPETS ETC OR INTER NAL LEAKAGE IN BY PASS TOW VALVE By Pass Tow Valve Does Not Operate Correctly CLEAN TRANSAXLE TRACTOR OF ACCUMULATED DEBRIS REPAIR OR REPLACE DAMAGED COMPONENTS AD JUST FOR PROPER OPERATION CHECK BY PASS TOW VALVE CONTROL FOR BENT BROKEN DISCONNECTED OR BINDING LINKAGE CHECK BY PASS TOW VALVE CONTROL FOR BENT BROKEN DISCONNECTED OR BINDING LINKAGE CORRECT...

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Husqvarna Tuff Torq K61, Service Manual

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