Husqvarna Tuff Torq K61 Manuel utilisateur
i
T a b l e o f C o n t e n t s
Ordering Replacement Parts Online .................................ii
Icons Used in this Manual .....................................................iv
Recommended Tools and Equipment .............................iv
Serial Number Locations .......................................................iv
Specifications: ...........................................................................iv
Disassembly of Transaxle ..........................1
Axel Shafts and Differential Gear Assemblies ...............7
Axle Seal Removal ...................................................................8
Axle Shaft and Bushing Tolerances ...................................7
Brake Assembly Removal ......................................................1
Bypass Valve Removal ...........................................................4
“C” Arm Removal .....................................................................3
Center Case & Motor Shaft Ass’y Removal ......................9
Center Case Removal .............................................................10
Cylinder Block (Motor) Assembly Removal ....................10
Cylinder Block Assembly (Pump) Removal .....................12
Differential Gear Assembly Removal ................................8
Differential Gear Assembly Removal ................................5
Differential Pinion Shaft and Gear Tolerance ................8
Drain Oil ......................................................................................1
Filter Removal ...........................................................................3
Final Pinion Shaft and Bushing Tolerances ....................5
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 Differential Gear Assembly ..................30
Before Starting Assembly .....................................................18
Bleeding Air from Hydrostate Oil Circuit .........................36
Brake Assembly ........................................................................35
Bypass Shaft Assembly ..........................................................18
Center Case Assembly ...........................................................27
Cylinder Block (Pump) Assembly .......................................24
Differential Gear Assembly ..................................................30
Lower and Upper Case Assembly ......................................33
Motor Shaft/Center Case Assembly ..................................28
Motor Shaft Assembly ...........................................................25
Oil Change Frequency ...........................................................37
Oil Requirement .......................................................................37
Final Pinon Shaft Assembly .................................................32
Post Assembly Procedures ...................................................36
Pump Shaft Assembly ............................................................22
Swash Plate Assembly ............................................................24
Troubleshooting and Diagnosis Guides ....38
iv
Icons Used in this Manual
This symbol identifies the presents of IMPOR-
TANT, if not critical, information.
This symbol is intended to alert you of important
technical information and/or maintenance procedures
which will better assist you in the disassembly and re-
assembly of the Transaxle.
This symbol offers suggestions which will bet-
ter assist you in the disassembly and reassembly of
Transaxle.
This symbol indicates when an application of
grease or oil is to be applied to the part prior to its as-
sembly.
Recommended Tools and Equipment
1. Transaxle Service Stand (Part Number 1111)
2. Black Electrical Tape
3. Needle Nose Pliers
4. O.D. Retaining Ring Pliers
5. I.D. Retaining Ring Pliers
6. Neoprene Hammer
7. Ball Peen Hammer
8. Telescoping Magnetic Pickup
9. Flathead 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 in.)
Maximum Static Weight on Axle ........265 kg (584 lbs.)
Weight (Dry) ...............................................17.5 kg (38 lbs.)
Brake .............................................................Dry Band
Brake Capacity ...........................................390 N-m (288 ft. lbs.)
.........................................................................at 245 N m (55 lbs.)
.........................................................................Brake Force
Differential ..................................................Automotive Type
.........................................................................Bevel Gears
Gears .............................................................Heat-Treated
Automatic Neutral Return .....................Standard
Housing ........................................................Aluminum Die Castings
Tow Value ....................................................Std. (Brake Release)
Oil ...................................................................10W 30 Class CC or CD
Oil Capacity ................................................3.3 liters (3.5 qts.)
Serial Number Locations
Service Stand (Part Number 1111)
This manual is applicable for repair of all (9) K61 models
built and distributed by Tuff Torq.
K61C, K61D, K61E, K61F, K61I, K61J, K61M, K61N, and
K61O
1
Tuff Torq K61 Hydrostatic Transaxle
Drain Oil
Before beginning tear-down clean work area
thoroughly and cover workbench with clean paper.
This is extremely important as just one grain of sand
can cause damage to the Hydrostatic Rotating Group
in the Transaxle.
1. Remove the Oil Drain Plug (12 mm wrench) from the
Lower Case of Transaxle and drain oil. (Fig. 1)
2. Remove the Connector (14 mm wrench) from the Center
Case, through the Lower Case and drain the oil from the
Hydrostatic Rotating Groups. (Fig. 1)
Fig. 1, Oil 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 (12mm
wrench) and detach the Brake Assembly. (Fig. 2)
4. Remove Snap Ring (Snap Ring Pliers) and the Brake
Drum from Brake Shaft. (Fig. 2)
Fig. 2, Brake Assembly Removal
Inspect all brake components for wear or dam-
age. Replace as necessary.
Brake drum and brake band are to be free from
oil and dust.
Disassembly of Transaxle
2
Fig. 3, Levers and Arms Removal
Shock Absorber and Control Arms Removal
(On K61 Models where applicable)
1. Remove the Shock 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
3
Tuff Torq K61 Hydrostatic Transaxle
Lower Case Removal
1. Place the Transaxle on a Service Stand in the serviceable
position (Lower Case up), to keep it steady during tear-
down. (See “Recommended Tools and Equipment”).
Service Stand (Part Number 1111) can be or-
dered online or through your local Tuff Torq distribitor.
See page iv, “Recommended Tools and Equipment.”
2. Remove the (14) bolts (8 mm) securing the Transaxle’s
Upper and Lower Cases. Lift the Lower Case away from
the Upper Case, exposing the internal parts.
(Fig. 5)
Fig. 5, Upper 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 Removal
Install a new filter any time case halves are
separated.
“C” Arm Removal
1. Disconnect “C” Arm from the Bypass Shaft by applying
slight sideward pressure to the spring loaded Push Pins.
This will keep them from springing out. With the Push
Pins secure, lift the “C” Arm off the Push Valve Bypass
Shaft. (Fig. 8, 9)
Fig. 8, “C” Arm Removal
4
1. Remove (2) Push Pins, Springs, and Bypass Valve from
the Center Case. (Fig. 9)
Fig. 9, Push Pin and Bypass Valve Removal
Final Pinon Assembly
1. Remove the Final Pinion Assembly from the Upper Case
from its seated 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 Removal
5
Tuff Torq K61 Hydrostatic Transaxle
2. Measure the I. D. (Y) of the “loose” Bushing. (Fig. 12)
3. If the clearance (Y-X) is > 0.50 mm (.019 in), replace the
Final Pinion Shaft and/or Bushing.
◆ Example of an Acceptable Tolerance:
Pinion Shaft O. D. (X) = 14.79 mm
Bushing I. D. (Y) = 15.27 mm
Y (15.27 mm) - X (14.79 mm) = 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, Final Pinion Shaft and “Loose” Bushing Clearance
Differential Gear Assembly Removal
6
Rotating the Axle until open end of C-Ring is
facing downward will prevent C-Ring from dropping into
Upper Case.
5. Carefully back out and remove the Left and Right Axle
Shafts. (Fig. 14, 16)
6. Remove (2) “loose” Bushings from the Upper Case.
(Fig. 16)
Inspect the Axle Shafts and Bushings for scor-
ing, pitting, discoloration, damaged ring grooves, and
chipped or broken splines. Replace as necessary.
Fig 14, Differential Gear Assembly and Axle Removal
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 shaft.
4. With the Thrust Washers and C-Rings removed, hold
the Gear Assembly in place. Carefully back out both
Axle Shafts until the shafts splines clear the Side Gears.
Remove the Gear Assembly and inspect components for
wear or damage. (Fig. 15)
7
Tuff Torq K61 Hydrostatic Transaxle
Axle Shaft and Bushing Tolerances
1. Using calipers (digital recommended) measure the O. D.
(X) of the Axle Shaft. (Fig. 15)
Fig. 15, Axle Shaft and “Loose” Bushing Clearance
2. 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 Assemblies
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