K61 Service Manual ()
Contents
1. wear or damage Fig 15 Tuff Torq K6 Hydrostatic Transaxle Axle Shaft and Bushing Tolerances 1 Using calipers digital recommended measure the O D 2 Measure the I D Y of the Loose Bushing Fig 15 X of the Axle Shaft Fig 15 3 If the clearance Y X is gt 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 gt the wear limit of 0 35 mm replacement is necessary Fig 15 Axle Shaft and Loose Bushing Clearance Axel Shafts and Differential Gear Assemblies Bushing Thrust Washer Pinion Shaft Pinion Gear Axle Shaft Left Side Gear Final Gear Axle Shaft Right Fig 16 Differential Gear and Axles 7 Differential Gear Assembly Removal Axle Seal Removal 1 Remove the Differential Side Gears Thrust Washers Dif 1 After the Differential Gear Assembly and Axles have ferential Pinion Gears and the Differential Pinion Shaft been removed take out the 2 Axle Seals at each end of from the Final Gear Fig 17 the Upper Case Fig 19 2 Inspect the Side and Pinion Gears and Pinion Shaft for scoring pitting discoloration and chipped or broken teeth Side Gear Thrust Washer Pinion Shaft Final Gear Fig 19 Axle Seal Removal A Extreme caution should be taken when remov2. Fig Bypass Shaft Assembly Q Rather than lubricating packing items O rings and Seals in advance apply a light coating of grease just prior to their installation This will minimize the pos sibility of debris collecting of packing items while wait ing to be installed Since the Bypass Shaft is spring loaded it is recom mended that the Release Valve Tow Arm be connected before proceeding From the reverse side of the Upper Case mount the Release Valve Arm onto the Bypass Shaft then align and secure with Roll Pin Fig 2 Release Valve Tow Arm Fig 2 Release Valve Arm Assembly Always install Roll Pins with the slit on a horizontal plane This will enable the pin greater holding ability Roll Pin Roll Pin Slit Horizontal Plane Fig 2a Roll Pin Installation Tuff Torq K6 Hydrostatic Transaxle Interlock Linkage If Applicable 1 Place the Upper Case back to the Service Position then attach the Bypass Rod to the Bypass Shaft Fig 3 Bypass Shaft Fig 3 Bypass Rod Assembly Brake Shaft Assembly If Applicable 1 Install a new O ring onto the Brake Shaft Fig 4 2 Check Bushing for damage or exceptionable wear replace if necessary Fig 4 Bushing amp Snap Ring Brake Shaft Brake Shaft Fig 6 Brake Shaft amp Return Spring Assembly Fig 4 Brake Shaft Assembly Return Spring NZP Apply a light coating of grease to the surface of the new O ring an
3. TUFF TORR SERVICE MANUAL Ko l 4 4 4 Z ie a ge OM KU KAY on N WON Li A Sa lt HYDROSTATIC TRANSAXLE DRIVING YOUR BEST IDEAS Table o f Ordering Replacement Parts Online ji Icons Used in this Manual sssessssesssesssecsssersssesssessseesseess iv Recommended Tools and Equipmeni iV Serial Number Locati OnS Emeereeerekeeee iv SDECINGAU ONS Yen DD O iV Disassembly of Transaxle 1 Axel Shafts and Differential Gear Assemblies 7 Axle Seal Removal nmmeneeeeeeeeeeeeeeeeeeene 8 Axle Shaft and Bushing Tolerances 7 Brake Assembly Removal ss sssesssesseessessssesseesseessesseesseessee 1 Bypass Valve Removal ccsssssscsssssssesecsssesesecessssecsesseeseseees 4 C Arm Removal Pe 3 Center Case amp Motor Shaft Ass y Removdl 9 Center Case Removal csssscsssssecsssssecssscsssssscessecscessecsceees 10 Cylinder Block Motor Assembly Removal 10 Cylinder Block Assembly Pump Removdl 12 Differential Gear Assembly Remov l 8 Differential Gear Assembly Remov l 5 Differential Pinion Shaft and Gear Tolerance 8 bee PPP 1 Filter Removal PSA 3 Final Pinion Shaft
4. gt Forward Reverse U R R Side Side i E Variable and Reversible Flow Pump 0 10 cc rev Reverse Travel EON Ge Ye a MOTOR NEZ i lt P i 10 cc rev T 5 H L D f j e 0 9 H CHECK VALVES xr v P i R E S m E ilter N U Forward Reverse j a Side Side R PUMP E Variable and Reversible Flow Pump 0 10 cc rev Assembiy of Transaxle Before Starting Assembly Before starting the assembly of the Transaxle check all parts to ensure that they are clean and free of any foreign debris this includes your work area and tools Have on hand a new Seal Kit 19215499150 Check contents of kit for possible defects before installation Note that the kit is designed to cover all K61 models You may or may not use all the items in the kit on your particular model The Seal Kit as well as other parts necessary for replacement can be ordered on line by visiting Tuff Torq s Web Site at www tufftorg com See Ordering Replacement Parts page ii Bypass Shaft Assembly 1 Place the Upper Case on a service stand in the service position flange side up Install a new O ring onto the Bypass Shaft Install the Spring onto the Bypass Shaft Install the Spring and Bypass Shaft into the hole on the Upper Case Fig 1 NP 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 Bypass Shaft Upper Case
5. 3 From the Catalog Order page select your transaxle model e g K61 Click on K61 to f nd the serial number for your model Ref Page 4 From the Model Series page click on your Model to enter the Serial Number Range page Ref Page 5 TUFF TORT CATALOG 4 Lan catalog browser P Select Your Transaxle Model anow TUFF rong race Kale REICJOHM DEERE l TEZ TEA Dl E A 11j Ci See PERE lines F u n i r um a Tae D ADE aE Tibii france Coe FACE od LESTE KHWHEFLI SEOs TAX TO MIBI1 MA hica TE dili PALIK Tax TUFF TORT CATALOG Catalog browser li oer pune Select Your Serial Number Range j dade rere Pong KALE OOO 09246 k den r EWI EASTIGA TATRA ivea fara j Tiiamaria P j mom LE JLTAN T rane KALE ojast 008038 KaTE BTI A P 4444548 ji CAFAL DE Cawan KALE OTT li SiAAEN KOSTEKA BK 13454048 j OORTaCT as aca ai Ton tert KALATIA T i Ka KALE Monjen 2175 OG GTA FP HHH k l l uj Paine I an MEAT P ede KOIE STI A PT cay Tuff Torq K6 Hydrostatic Transaxle Page4 Page 5 ios lji mewe j ogm b asorr rere PO TT bd conan r zn roi li w n Fira ji Carat oma EL li correct us narr K lE 003039 004217 THIS Khl STOA ek TUFF TORT ATALOG product explorer V d r ESER er rune roug j z r j TER l PPER CASE KIT DEN b panara Je ull Teng
6. SHIFT CONTROL LINKAGE BENT OR BINDING TRANSAXLE SHIFT CONTROL ARM LEVER FAILED OR WORN BRAKE DRAGGING OR PARTIALLY ENGAGED FITTING 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 42 POSSIBLE SOLUTION 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 LINKAGE PER PROPER PROCEDURE REPLACE SHIFT CONTROL ARM LEVER AND NEW ROLL PIN ADJUST SHIFT LINKAGE PER PROPER PROCEDURE BRAKE LINKAGE BROKEN BENT BINDING OR OUT OF ADJUSTMENT MAKE NECESSARY CORRECTIONS AD JUSTMENTS TORQUE FITTING AND ALLEN PLUG TO 2 0 2 5 KG M 15 18 FT LBS TRANSAXLE REPLACEMENT OR REPAIR REQUIRED Troubleshooting and Diagnosis Guides POSSIBLE CAUSE Slows Down Under Heavy Load High Operating Temperature Stall Condition INCORRECT OIL OIL LEVEL IN TRANSAXLE TRANSAXLE DRIVE BELT OUT OF ADJUSTMENT WORN OR FRAYED INADEQUATE INSUFFICIENT COOLING BRAKE DRAGGING OR PARTIALLY ENGAGED TRANSAXLE IS OVERLOADED LOSS OF ENGINE RPM S INTERNAL DAMAGE TO ROTATING GROUPS OR CEN TER CASE Lower Power Both Directions AXLE WHEEL HUB SLIPPING GRASS OR OTHER DEBRIS INTERFERENCE INCORRECT OIL
7. place Soe nny C Arm onto Bypass Shaft Fig 37 Center Case i p Bypass Shaft Fig 36 Magnet Mounting Bypass Valve Center Case Assembly Q Magnet must be oriented by rotating clockwise Fig 37 Actuating Valve Assembly against Center Case side while tightening Bolts The Lower Case will not mate properly with Upper Case if Magnet is not correctly located 29 Differential Gear Assembly 1 Install the 2 Differential Pinion Gears to Differential Pinion Shaft Fig 38 2 Install the Differential Pinion Assembly Pinion Shaft and 2 Pinion Gears within the Final Gear Fig 38 3 Position the 2 Thrust Washers aginist Pinion Shaft body and Final Gear Fig 38 4 Position the 2 Differential Side Gears next to Thrust Washers Fig 38 Thrust Washer Side Gear Pinion Shaft Final Gear KO SS Za O Axle Shafts and Differential Gear Assembly 1 Place new Seals onto Left and Right Axle Shafts Fig 39 NZP Apply a light coating of grease to Seal before installation Also apply a small amount of grease to the chamfer of bore Q 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 Axle Shafts into Upper Case 3 Place the 2 loose Axle Bushings into corre
8. CAUSE Note If your specific problem and or solution is not listed below consult a qualified Tuff Torg Distributor Transaxle Noise DEBRIS INTERFERING WITH MOVING PARTS INCORRECT OIL OIL LEVEL IN TRANSAXLE BRAKE DRAGGING OR PARTIALLY ENGAGED TRANSAXLE DRIVE BELT OUT OF ADJUSTMENT RUB BING SOMEWHERE OR FRAYED FAN CRACKED BROKEN OR STRIKING SOMETHING BEARING ON IDLER PULLEY WORN EXCESSIVELY INPUT SHAFT PULLEY LOOSE OR DAMAGED BY PASS VALVE ORIFICE LOCATED IN WRONG PORT HYDROSTATIC OIL FILTER PLUGGED INTERNAL DAMAGE TO ROTATING GROUPS AND DIF FERENTIAL ASSEMBLY 38 POSSIBLE SOLUTION 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 FAN BLADE INTERFERENCE MAKE NECESSARY CORRECTIONS ADJUSTMENTS INSPECT IDLER PULLEY COMPONENT MAKE NECES SARY CORRECTIONS ADJUSTMENT INSPECT PULLEY PULLEY SPLINES SNAP RINGS AND INPUT SHAFT SPLINES FOR DAMAGE MAKE NECES SARY CORRECTIONS ADJUSTMENTS CENTER CASE REPLACEMENT REQUIRED TRANSAXLE REPLACEMENT OR REPAIR REQUIRED TRANSAXLE REPLACEMENT OR REPAIR REQUIRED Troubleshooting and Diagnosis Guides POSSIBLE CAUSE Brakes Malfunction BRAKE LINKAGE BROKEN BENT BINDING OR DIS CONNECTED BRAKES OUT OF ADJU
9. Filter from the Center Case and discard position Lower Case up to keep it steady during tear Fig 7 down See Recommended Tools and Equipment A 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 8 mm Bolt 2 of 14 Fig 7 Filter Removal Q Install a new filter any time case halves are separated C Arm Removal 1 Disconnect C Arm from the Bypass Shaft by applying GSj slight sideward pressure to the spring loaded Push Pins D8 r separation does not occur easily a screw This will keep them from springing out With the Push driver can be inserted at any of the 4 pry points indi Pins secure lift the C Arm off the Push Valve Bypass cated by the black arrows Fig 6 Shaft Fig 8 9 C Arm Center Case Push Valve Bypass Shaft Fig 6 Pry Points W 23 Care should be taken not to damage the Hous Fig 8 C Arm Removal ing Sealing lips while prying apart Remove any old sealant residue from both case halves Bypass Valve Removal Final Pinon Assembly 1 Remove 2 Push Pins Springs and Bypass Valve from 1 Remove the Final Pinion Assembly from the Upper Case the Center Ca
10. IN TRANSAXLE TRANSAXLE DRIVE BELT OUT 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 41 POSSIBLE SOLUTION REPLACE SEALS AND O RINGS AS REQUIRED INSPECT DRIVE BELT REPLACE AND OR ADJUST PER PROPER PROCEDURE INSPECT IDLER PULLEY COMPONENTS MAKE NECES SARY CORRECTIONS CLEAN TRANSAXLE TRACTOR OF ACCUMULATED DEBRIS TRANSAXLE REPLACEMENT OR REPAIR REQUIRED TRANSAXLE REPLACEMENT OR REPAIR REQUIRED CHECK KEYS FOR PROPER INSTALLATION CHECK OIL LEVEL IN EXPANSION TANK SAE 10W30 MOTOR OIL INSPECT DRIVE BELT REPLACE AND OR ADJUST PER PROPER PROCEDURE REPLACE MISSING OR DAMAGED ROLL PIN REMOVE ACCUMULATED DEBRIS REPAIR AND OR REPLACE DAMAGED OR MISSING COMPONENTS DISENGAGE PARKING BRAKE INSPECT KEYS OR SPLINES ON ENGINE AND TRANSAXLE PULLEYS REPLACE DAMAGED OR MISS ING COMPONENTS Troubleshooting and Diagnosis Guides POSSIBLE CAUSE No Drive continued BY PASS TOW VALVE ACTIVATED INPUT SHAFT SPLINES DAMAGED BY PASS TOW VALVE COMPONENTS DAMAGED INPUT SHAFT NOT ROTATING PUMP COMPONENTS INTERNAL DAMAGE TO ROTATING GROUPS CENTER CASE AND DIFFERENTIAL ASSEMBLY HYDROSTATIC OIL FILTER PLUGGED No Drive One Direction GRASS OR OTHER DEBRIS INTERFERENCE SPEED
11. LL AI li PAMA Pim h ji 2a T dl dl GER N n Toll Terq PN heswnser a EERTE i baserr 142154142408 i HAZE Poca Pal C KSIE STIMA 79215434140 O OOOO O OO ST WEREWE OT oo i 1 FIRAT laze 2T BHANN UPPER CASE KI i 5i 29 24 1 HHMI LOWE kul l Biais 4 WEIMMIIO CAP tal 0 70 HSNI My a l s ase Zrim wy m i 1 73 ee 7 Zi SE AP af n ase IORI DEAR a i 2 10 STAR TAPPI B HE ii l lk di2 TAPRIN a t 030 ja tini M SEE aza Page 6 iii Having your Model and Model Series click on the serial number to enter the Online Ordering page for you Transaxle Ref 6 Navigate through the exploded parts illustration until the desired part has been identified Take note of the part s figure number Locate the part number in the parts listing You can add the part to your shopping cart and return to the exploded illustration or click on the item to go to the Product Explorer page for additional detail about the part Ref Page 7 Thank you for visiting and ordering online with Tuff Torq Icons Used in this Manual A This symbol identifies the presents of IMPOR TANT if not critical information Q 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 N 7 Q This symbol offers suggestions which will bet ter a
12. ing 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 Q Fig 7 Differential Gear Assembly Seals should be replaced every time the Axles are removed Differential Pinion Shaft and Gears Tolerance 1 Using calipers digital recommended measure the O D 2 Measure the l D Y of the Pinion Gears Fig 18 X of the Pinion Shaft Fig 18 3 If the clearance Y X is gt 0 50 mm 0 019 in replace the WD Pinion Shaft and or Pinion Gears Example of an Unacceptable Tolerance Pinion Shaft O D X 14 75 mm Pinion Gear I D Y 15 30 mm Y 15 30 mm X 14 75 mm 0 55 mm of clearance This is gt the wear limit of 0 50 mm replacement is necessary Fig 18 Differential Pinion Shaft and Pinion Gears Clearance Tuff Torq K6 Hydrostatic Transaxle Hydrostatic Pump Removal Center Case Cylinder Block Assembly Motor Housing Motor Shaft Seal Snap Ring Serial Number Slide the Brake Drum onto the Motor Shaft to provide a means of grip Brake Drum Snap Ring ing and lifting the Center Case and Mo tor Shaft Assemblies from the Upper Case Fig 20 Center Case and Motor Shaft Assemblies Magnet Removal Center Case amp Motor Shaft Ass y Removal 1 Loosen 3 Bolts 10 mm removing one on the Cen 2 After removing the remaining two bolts h
13. into Upper Case Reduction Gear Fig 43 Final Pinion Shaft D gt Washer Q 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 Bearing Final Pinion Shaft Reduction Gear ko Fig 43 Final Pinion Shaft Assembly 32 Tuff Torq K6 Hydrostatic Transaxle Lower and Upper Case Assembly 1 Place anew Filter over groove of Center Case 2 Apply a thin even bead of sealant to mating surface of Lower Case following along the inside surface of bolt holes Be sure to apply sealant aroung center bolt hole Fig 45 Filter Q 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 Center Case ing of the Lower Case onto the Upper case 3 Position Lower Case onto Upper Case Press together Fig 44 New Filter Install AP When installing a new Filter apply a film of clean oil onto the rubber seals Fig 44 Sealant Area Sealant Area Sealant Area Fig 45 Sealant Application to Lower Case 33 Lower and Upper Case Ass y continued 4 Install 1 M8x75 Bolt arrow 14 2 M8x40 Bolts ar rows 8 amp 10 and 11 M8x30 Bolts arrows 1 13 to Lower Case Upper Case Fig 46 5 Torque Bolts
14. of the assembly i i i will result in the replacement of the entire assembly 3 Installation involving a new Bearing Fig 25 Press Bearing into position oe e Install Washer Seat Snap Ring in the Motor Shafts groove amp To avoid the pistons from dropping out during assembly position fingers around the cylinder in order to apply pressure on each of the five pistons Fig 23 5 Install Snap Ring in front of new Seal Fig 25 4 Install a new Seal onto the Motor Shaft Fig 25 Piston Snap Ring Washer Bearing Cylinder Fig 23 Finger Placement During Assembly Picton rales mg Nieto Shari Snap Ring Fig 25 Motor Shaft Assembly N 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 Fig 24 Cylinder Block Assembly Installation Q If any of the components of Cylinder Block As sembly are damaged they must be replaced with a complete Cylinder Block Assembly Individual compo nents are not serviced separately 25 Motor Shaft Assembly continued 6 Install the Thrust Bearing Group into the Motor Housing Comprising of 2 Thrust Plates and 1 Thrust Bear ing the Thrust Bearing Group should be oiled and placed into the Motor Housing Starting with the thin Thrust Plate followed by the Thrust
15. 12 mm wrench utilizing the tightening sequence diagram Fig 46 Tightening torque 2 3 2 5 kg m 22 6 24 6 N m 17 18 ft Ibs Fig 46 Torque Sequence for Upper amp Lower Case 6 Install Oil Drain Plug 12 mm wrench with new Seal Washer into Lower Case 1 3 1 7 kg m 12 8 16 7 N m 113 148 in Ibs Tightening torque 7 Install 2 new O rings and the 1 8 plug 5 mm hex wrench onto Connector Pressure Fill Plug NP Apply grease to surface of O rings Q 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 Connector 1 8 Pressure Plug Oil Drain Plug Seal Washer Fig 47 Oil Plug amp Connector Install Q Before installing the Connector fill transmission rotor groups with new oil through the connector port of Center Case while hand rotating Motor Shaft using Brake Drum for gripping assistance This procedure is effective for quick air bleeding Brake Assembly 1 Install the Brake Drum and Snap Ring onto Motor Shaft Fig 49 2 Install the Brake Band Assembly tighten 3 Bolts by hand Fig 48 49 Q Glean oil and dust from the Brake Band and Brake Drum before installing 3 Center the Brake Band around the Brake Drum by manu ally activating left to right the Engagement Lever While maintaining pressure to the Engagement Lever tighten usi
16. ARD AND LOCKED UP WHEN TRACTOR IS PUSHED REARWARD TRANSAXLE REPLACEMENT OR REPAIR REQUIRED Troubleshooting and Diagnosis Guides POSSIBLE CAUSE ACCUMULATION OF GRASS AND OR OTHER DEBRIS INTERFERENCE BY PASS TOW VALVE CONTROL LINKAGE BENT BRO KEN DISCONNECTED OR BINDING BY PASS TOW VALVE PARTIALLY ACTIVATED BY PASS TOW VALVE ACTIVATED BY PASS TOW ORIFICE LOCATED IN WRONG PORT BINDING BROKEN OR MISSING INTERNAL COMPO NENTS PUSH PIN SPRING POPPETS ETC OR INTER NAL LEAKAGE IN BY PASS TOW VALVE 45 POSSIBLE SOLUTION 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 LOCATION IS INDICATED BY CREEP OF TRACTOR S WHEEL WHEN PUSHED FORWARD AND LOCKED UP WHEN TRACTOR IS PUSHED REARWARD CENTER CASE REPLACEMENT REQUIRED TRANSAXLE REPAIR REQUIRED
17. Bearing and finally the thick Thrust Plate Fig 26 N Apply a light coating of oil to the Motor Housing machined surfaces for Thrust Bearings 7 Install Motor Shaft Assembly through hole in Motor Housing Fig 26 8 Install Snap Ring and Spring onto Motor Shaft Fig 26 NZP 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 Thrust Bearing Snap Ring Motor Housing Motor Shaft Fig 26 Motor Shaft Housing Assembly 9 Place the 5 washers springs and pistons into Motor Cylinder Block Fig 27 26 Cylinder Block Piston Fig 27 Motor Cylinder Block 10 Align splines of the Cylinder Block Assembly and the Motor Shaft then press together until pistons are posi tioned against Motor Housing Thrust Bearing Fig 28 Q Motor Housing Assembiy is installed so that dimples are showing facing up Fig 28 A If Motor Housing Assembly is oriented 180 op posite dimples facing downward during installation axles will rotate in opposite direction i e axles will ro tate forward when they should be rotating in reverse Cylinder Block Assembly Z Motor Housing Assembly Fig 28 Motor Cylinder Block Assembly Tuff Torq K6 Hydrostatic Transaxle Center Case Assembly The Center Case Assembly is com
18. OEM Customers A Special yt han Dee Cg i ae service and mpak kmcellitns in loring and cedering parm for parse TIR TL ki Cinan Ta Tu i Torg lk ere l embar service wbai i peo week tate pects freee by ipi DEL ug m DRIVING YOUR BEST IDEAS Page 1 WELCOME l Beane ATu Tom wa ofer rar coer Gui paii A A ree pie A ere nl ties ie and eer ee ji Prana rei li K l r Tl peer pifre inure Tut Tor s r b corepiede lak of reramai dand pirti bo Peig fie eur reb b asper rar mag ee beran mavi T rob Of Dur GEMA ruvlemen hia metabo li d dil ert m mU pedi FS l hong ana Dalan DATE for But Tor rara ITEM SEW kl my nayene wenay kalana e inn j meno CELE ine CTV DE WEL MI POZN TOL WET COMP B EWI OF PENS ETO aan ear Dir BOD j raaaya x a re as Thea ou kur viniting aed cenke onna wih TaT Tam ji KA FAN dd OW BEN TH you ar m arieni user plese bag ko ne ara a the pabu oder DebeT GERI Biaan Karta buz Bie date forrest ied on Ena nihe i dem For daimi Ob igit to the aM G Jura S T CONT L yo am hot m CEM ad or methine terete R N rz you my nakl B OAL VON ep ier D desk Plak ater poor brandi bebe and pts wil Se ceed b Ew MPAA T eet d B TUFF TORM CATALOG stare browser ji H kan J iaa Select Your Transaxle Model ABOVE DEWE FT Kas KE TOTEM i AFO CENTIER Bas EE TEARIK AYE a j TIRAL aang ries koe k l E E E Page 3 tu f f tor gd ii c o m At Tuff T
19. OIL LEVEL IN TRANSAXLE ENGINE RPM NOT MAXIMUM PARKING BRAKE ENGAGED BRAKE DRAGGING OR ENGAGED SPEED SHIFT CONTROL LINKAGE BENT OR BINDING CONNECTOR FITTING NOT OIL PLUG LOOSE AT BOT TOM OF CASE ENGINE OR TRANSAXLE PULLEY LOOSE OR DAM AGED ON RESPECTIVE SHAFTS 43 POSSIBLE SOLUTION CHECK OIL LEVEL IN EXPANSION TANK SAE 10W30 MOTOR OIL INSPECT DRIVE 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 CHECK OIL LEVEL IN EXPANSION TANK SAE 10W30 MOTOR OIL ADJUST ENGINE SPEED DISENGAGE PARKING BRAKE OUT OF ADJUSTMENT MAKE NECESSARY CORREC TIONS ADJUSTMENTS REPAIR OR REPLACE DAMAGED COMPONENTS AD JUST SHIFT LINKAGE PER PROPER PROCEDURE TORQUE FITTING AND ALLEN PLUG TO 2 0 2 5 KG M 15 18 FT LBS INSPECT PULLEYS PULLEY SPLINES AND SNAP RINGS MAKE NECESSARY CORRECTIONS NOTE IF INPUT SHAFT SPLINES ARE DAMAGED OR WORN INPUT SHAFT REPLACEMENT MAY BE REQUIRED Troubleshooting and Diagnosis Guides POSSIBLE CAUSE Lower Power Both Directions continued BY PASS TOW VALVE PARTIALLY ACTIVATED INTERNAL DAMAGE TO ROTATING G
20. R PROPER PROCEDURE REPLACE DAMAGED OR MISSING COMPONENTS AD JUST SHIFT LINKAGE PER PROPER PROCEDURE REPLACE SHOCK ABSORBER MAKE NECESSARY CORRECTIONS ADJUSTMENTS TRANSAXLE REPLACEMENT OR REPAIR REQUIRED Troubleshooting and Diagnosis Guides POSSIBLE CAUSE 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 RUST PREVENTATIVE APPLIED AT MANU FACTURER S FACILITY EXCESSIVE OIL IN TRANSAXLE DUE TO OVERFILL LEAKING FROM EXPANSION TANK DUE TO HEAT EXPANSION TRANSAXLE OVERHEATING DUE TO EXCESSIVE LOADING LEAKING FROM EXPANSION TANK DUE TO EXCESSIVE RISE IN OIL TEMPERATURE EXPANSION TANK AND CONNECTION COMPONENTS INPUT SHAFT SEAL AXLE SHAFT SEAL DRAIN PLUG LOWER CASE FITTING CONNECTOR AND ALLEN PLUG CASE BOLTS 40 o M POSSIBLE SOLUTION REMOVE ACCUMULATED DEBRIS REPAIR OR RE PLACE DAMAGED COMPONENTS ADJUST PER PROPER PROCEDURE CHECK OIL LEVEL IN EXPANSION TANK SAE 10W30 MOTOR OIL REPLACE SHOCK ABSORBER TRANSAXLE REPLACEMENT OR REPAIR REQUIRED THESE CASES APPEAR TO BE LEAKING BUT DO NOT REQUIRE REPAIR ALL LEAKS SHOULD BE INVES TIGATED TO DETERMINE SOURCE OF LEAKAGE ADJU
21. ROUPS SWASH PLATE AND COMPONENTS CENTER CASE OR DIFFER ENTIAL ASSEMBLY HYDROSTATIC OIL FILTER PLUGGED Low Power One Direction AXLE WHEEL HUB SLIPPING GRASS OR OTHER DEBRIS INTERFERENCE INCORRECT OIL OR OIL LEVEL IN TRANSAXLE PARKING BRAKE ENGAGED BRAKE DRAGGING OR PARTIALLY ENGAGED SPEED SHIFT CONTROL LINKAGE BROKEN BENT OR BINDING CONNECTOR FITTING NOT OIL PLUG LOOSE AT BOTTOM OF CASE BY PASS TOW VALVE PARTIALLY ACTIVATED BY PASS TOW VALVE ORIFICE LOCATED IN WRONG PORT INTERNAL DAMAGE TO ROTATING GROUPS SWASH PLATE AND COMPONENTS CENTER CASE BY PASS VALVE COMPONENTS OR DIFFERENTIAL ASSEMBLY 44 POSSIBLE SOLUTION 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 10W30 MOTOR OIL DISENGAGE PARKING BRAKE BRAKE LINKAGE BROKEN BENT BINDING OR OUT OF ADJUSTMENT MAKE NECESSARY CORRECTIONS AD JUSTMENTS REPAIR OR REPLACE DAMAGED COMPONENTS AD JUST SHIFT LINKAGE PER PROPER PROCEDURE TORQUE FITTING AND ALLEN PLUG TO 2 0 2 5 KG M 15 18 FT LBS CHECK BY PASS TOW VALVE CONTROL FOR BENT BROKEN DISCONNECTED OR BINDING LINKAGE CORRECT LOCATION IS INDICATED BY CREEP OF TRACTOR S WHEEL WHEN PUSHED FORW
22. ST OIL LEVEL IN EXPANSION TANK SAE 10W30 MOTOR OIL CONFIRM THAT TRANSAXLE IS NOT OVERHEATING WASH ALL EXCESS OIL AND ACCUMULATED DEBRIS OFF OF TRANSAXLE OPERATE MOWER UNTIL OPERATING TEMPERATURE BECOMES NORMAL CHECK AGAIN FOR OIL LEAKAGE TO FIND EXACT SOURCE MAKE NECESSARY CORRECTIONS ADJUSTMENTS SEE INPUT SHAFT SEAL REPLACEMENT PROCEDURE SEE AXLE SHAFT SEAL REPLACEMENT PROCEDURE REMOVE INSPECT AND REPLACE SEAL WASHER RE PLACE TEFLON TAPE ON ALLEN PLUG TORQUE PLUG TO 1 5 KG M 130 IN LBS CHECK OIL LEVEL REMOVE INSPECT REPLACE INNER AND OUTER O RINGS IF REQUIRED TORQUE FITTING AND 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 Troubleshooting and Diagnosis Guides POSSIBLE CAUSE Oil Leakage continued CASE HALVES IF TORQUE MEETS SPECIFICATIONS e MOTOR OUTPUT SHAFT SEAL BRAKE e BY PASS TOW CONTROL SHAFT O RING e SPEED SHIFT CONTROL SHAFT O RING e FULCRUM O RING EITHER BRAKE SHAFT O RING Input Pump Shaft Pulley Will Not Turn TRANSAXLE DRIVE BELT OUT OF ADJUSTMENT WORN FRAYED OR MISSING IDLER PULLEY SEIZED BINDING OR WORN GRASS OR OTHER DEBRIS INTERFERENCE INPUT PUMP SHAFT SPLINES DAMAGED EXTERNAL LY OR INTERNALLY INTERNAL DAMAGE TO ROTATING GROUPS CENTER CASE AND DIFFERENTIAL ASSEMBLY No Drive AXLE WHEEL HUB KEYS MISSING OR DAMAGED INCORRECT OIL LEVEL OR OIL
23. STMENT BRAKE DRUM AND BRAKE BAND ASSEMBLY COATED WITH OIL Transaxle Overheating POOR AIR CIRCULATION FAULTY AND OR DAMAGED FAN PULLEY INCORRECT OIL OIL LEVEL IN TRANSAXLE ACCUMULATION OF GRASS AND OTHER DEBRIS IN COOLING FINS OF TRANSAXLE TRANSAXLE DRIVE BELT OUT OF ADJUSTMENT OR DAMAGED BRAKE DRAGGING OR PARTIALLY ENGAGED BY PASS VALVE ORIFICE LOCATED IN WRONG PORT Creeps In Neutral SPEED SHIFT CONTROL LINKAGE BENT OR BINDING TRANSAXLE SHIFT CONTROL ARM LEVER FAILED SHIFT CONTROL ARM ROLLPIN O D AND LENGTH UNDERSIZED OR MISSING SHOCK ABSORBER DAMPER BENT RUSTY WORN OR MISSING NEUTRAL SETTING OUT OF ADJUSTMENT INTERNAL DAMAGE TO SHIFT CONTROL SHAFT SWASH PLATE AND COMPONENTS THRUST METALS BEARING PADS AND NEUTRAL RETURN SPRING 39 POSSIBLE SOLUTION CLEAN AND INSPECT TRANSAXLE FOR ACCUMULAT ED DEBRIS AND WORN LINKAGE COMPONENTS SEE PROCEDURE FOR PROPER ADJUSTMENT CLEAN BRAKE COMPONENTS WITH BRAKE CLEANER INSPECT FAN PULLEY FOR DAMAGE CHECK MOUNT ING HARDWARE MAKE NECESSARY CORRECTIONS ADJUSTMENTS CHECK OIL LEVEL IN EXPANSION TANK SAE 10W30 MOTOR OIL CLEAN TRANSAXLE TRACTOR OF ACCUMULATED DEBRIS MAKE NECESSARY CORRECTIONS ADJUSTMENTS BRAKE LINKAGE BROKEN BENT BINDING OR OUT OF ADJUSTMENT MAKE NECESSARY CORRECTIONS AD JUSTMENTS CENTER CASE REPLACEMENT REQUIRED REMOVE ACCUMULATED DEBRIS REPAIR OR RE PLACE DAMAGED COMPONENTS ADJUST PE
24. a 17 5 kg 38 Ibs she Pe Dry Band Brake CapaCity ueeeeeez 390 N m 288 ft Ibs at 245 N m 55 Ibs Brake Force Differential Automotive Type Bevel Gears cebr ree Heat Treated Standard HOUS NO ans aaa Aluminum Die Castings TO VA Oeno ds eat a Std Brake Release Poe en 10W 30 Class CC or CD Oil Capacity crcsccsasasesterasnsectdansssssenessenesenseser 3 3 liters 3 5 qts Disassembiy of Transaxle Drain Oil A 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 14mm wrench from the Center Case through the Lower Case and drain the oil from the Hydrostatic Rotating Groups Fig 1 Connector Oil Drain Plug Seal Washer Fig I Oil Drain Plug and Pressure Fill Plug removal Q Always install a new Seal Washer on the Drain Plug and new O rings on Pressure Fill Plug when reas sembling Tuff Torq K6 Hydrostatic Transaxle Brake Assembly Removal 1 Remove the Cotter Pin and Washer from the Brake Rod Assembly Fig 2 Remove the Brake Rod Assembly from Brake Arm B see Fig 3 by pivoting 90 degrees and sliding downward Fig 2 Loose
25. aft The side of the Brake Arm with the word UP should be visible then align and secure with Roll Pin Fig 10 Brake Arm IYAN ND 29 lt Th Fig 10 Brake Arm Assembly Mount the Brake Arm B onto the Brake Arm A then align and secure with Roll Pin Fig 11 Fig 1 Brake Arm B Assembly Place the Upper Case back to the Service Position and continue with the assembly of Transaxle Tuff Torq K6 Hydrostatic Transaxle Control Shaft 8 Fulcrum Assembly 1 Install a new O ring onto the Control Shaft Fig 12 3 Place the head of the Fulcrum between the legs of the Torsion Spring Fig 14 N Apply a light coating of grease to the surface of the new O ring Also apply a small amount of grease around the mating hole of Upper Case Torsion Spring Torsion Spring Control Shaft Fulcrum O Ring Ninan 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 Assembly See Swash Plate Assembly step 3 on page 24 Fig 15 Fig 12 Control Shaft Torsion Spring Assembly 2 Install a new O ring onto the Fulcrum If applicable for your model Fig 13 5 Align the Fulcrum and Control Shaft Assembly with mat P Apply a ligh
26. and Bushing Tolerances 5 Final Pinon Assembly sesesseesseessesssesseesseesssesseesseessesssesseessee 4 Final Pinon Assembly Remo v l 4 AV eV an Removal PPR o 14 Hydraulic Flow DiagraM ssessesssesseesseesssesseesseessesssesseessee 17 Hydrostatic Pump Removal s ssesssesseesseesseesseessesssesssesseessee 9 Levers Shafts and Linkage Remov al 16 Lower Case Removal sssessseseseessersseeosseossseosseessseosseosseesseess 3 Magnet Removal ssessesssessesseessessesseessessessersseoseessesseoseessessessee 9 Motor Housing Removal seessessesssessessesssesseessessesseessessessee 10 Motor Shaft Removal sssesssseessseessserssseesssseessseessseessseessseess 11 Pump Shaft ReMOVal seessessesssessesseeseessesseessesseessessesseeseessesss 15 Shock Absorber and Control Arms Removal 2 Swash Plate REMOV Al ecsecconcssessactcoscuaveccossansstaccetsentcsesamessescoeeees 13 Assembly of Transaxle 18 Contents Adjusting Neutral PROP O O 36 Axle Shafts and Differential Gear Assembly 30 Before Starting Assembly meeereeee 18 Bleeding Air from Hydrostate Oil Circuit 36 Brake Assembly esse eba ed nao 8 ko sko Ape 35 Bypass Shaft Assembly sseesssesssessseesssessssessseesseesssesssersseess 18 Center Case Asse
27. crum Shaft clockwise slowly until the Axle Shaft stops and mark the Transaxle Case Fig 51 10 Rotate mark on the Fulcrum clockwise to a position one 11 third 1 3 distance from the forward stop point Fig 51 Hold the Fulcrum Shaft with a 8 mm wrench and tighten the 17 mm Lock Nut Fig 57 Fulcrum Lock Nut Forward Stop Reverse Stop 4773 J Fig 51 Neutral Adjustment 12 Confirm no rotation of the Axle Shaft in neutral by slow 36 ly returning the Control Lever to neutral from forward and reverse Tuff Torq K6 Hydrostatic Transaxle Oil Change Freguency For consumer use in yard tractor and riding mower appli cations oil changing is not emphasized as most hom eowners are not eguipped or in the habit of changing transmission oil For most consumers the transaxle 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 reguire changing unless the transaxle is removed from the tractor or riding mower and opened for repairs Oil Reguirement Approximately 3 3 liters of SAE 10W30 Class CC or CD en gine oil K61 Hydrostatic Transaxle Fig 52 K61 Hydrostatic Transaxle 37 Troubleshooting and Diagnosis Guides POSSIBLE
28. d 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 Bypass Valve Rod 4 Place the Brake Return Spring under the Brake Shaft Fig 5 7 5 Hook the Brake Return Spring to the Brake Shaft see arrow then hook the opposite end of the spring to Brake Shaft the Upper Case housing see arrow Fig 6 Fig 7 Brake Shaft Bypass Rod Assembly 19 Brake Arm A Assembiy 1 Install a new O ring onto the Brake Arm Fig 8 4 2 Attach the Brake Rod to the Brake Arm then to the Brake Shaft Fig 8 9 NF 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 Brake Arm A Brake Rod Fig 8 Brake Arm Assembly 3 Secure the Brake Rod to the Brake Shaft with a Washer and Cotter Pin Fig 9 Pin amp Washer Return Spring Bypass Valve Rod Brake Rod Brake Shaft 6 Fig 9 Brake Rod Assembly Q With the Brake Linkage in place seat the Brake Shaft and the Brake Arm to their lowest position In order for the Roll Pin and the Brake Arm to align properly Fig 10 the Return Spring must not hin der the full positioning of the Brake Shaft Check linkage for proper operation adjust if necessary 20 3 From the reverse side of the Upper Case mount the Brake Arm onto the Brake Sh
29. ed measure the 3 Inspect the Fulcrum Cam for wear or damage replace if thickness of both Thrust Metals for wear If the clear required ance is lt 1 30 mm 0 051 in replace Thrust Metals as a l l set Fig 39 4 Remove and discard 2 O rings and replace with a fresh pair Fig 41 Swash Plate ____ Fulcrum O Ring S Thrust Metal CD O Ring Wear Limit 1 30 mm Ge Washer Fig 39 Thrust Metals Tolerance Nut Q Always replace the Thrust Metals worn beyond Fig 41 Fulcrum wear limits as a group 14 Pump Shaft Removal 1 Remove the Seal and discard Replace with new a Seal during reassembly Fig 42 Remove the large internal Snap Ring and lift the Pump Shaft from the Upper Case Fig 43 Q 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 Tuff Torq K6 Hydrostatic Transaxle 15 Seal Snap Ring Snap Ring Washer Snap Ring Pump Shaft Fig 43 Pump Shaft A Do not attempt to remove the press fit Bearing on the Pump Shaft unless it is damage or worn Re moval could result in damage to the Bearing Levers Shafts and Linkage Removal If Applicable 1 Remove the Control Shaft Assembly 2 Remove the Fulcrum Refer to page 14 for more details 3 Disconnect Snap Pin fro
30. ft Piston Spring Cylinder Block Piston S GS Thrust Plate Thrust Bearing Thrust Plate Shift Block Kit Fig 35 Swash Plate Removal Swash Plate 3 Remove the Thrust Bearing seated in the Swash Plate Fig 36 4 Remove the Swash Plate Fig 36 Thrust Metal Bearing 5 Inspect the press fit Bushing in the Swash Plate for burrs scoring pitting discoloration and wear If dam Fig 37 Cylinder Block Assembly amp Swash Plate age replace the Swash Plate The press fit Bushings are not serviceable separately A Do not attempt to remove the press fit Bushing in the Swash Plate If damaged replace Swash Plate Assembly press fit Bushing is included in the assem bly 13 Swash Plate Removal continued Fulcrum Removal 1 Remove the Nut 17mm and Washer from the Fulcrum Neutral Adjust Eccentric Fig 40 C CO STS Jj Washer A l Fulcrum zi SN a NS Fig 40 Fulcrum Removal from top of Upper Case Machined Ramp Surfaces z N gt AL Swash Plate Slot Fig 38 Swash Plates Machined Ramps Q 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 Return the Upper Case to its service position Flange side up and remove the Fulcrum Fig 41 7 Using calipers digital recommend
31. ithdraw the Motor Shaft from the Motor Housing If the Shaft doesn t back out freely check to see if Snap Ring was removed see step 6 Fig 29 Remove the Snap Ring and Washer Inspect the Washer for wear or damage and replace if necessary Fig 29 Snap Ring eq Washer Motor Housing Motor Shaft Snap Ring Fig 29 Motor Shaft Removal A There is no need to remove the press fit Bear ing on the Motor Shaft unless it is damaged or worn Snap Ring Pressed on Bearing Location Snap Ring Snap Ring Brake Drum Seal Fig 28 Motor Shaft Assembly 11 Hydrostatic Pump Removal continued Cylinder Block Assembly Pump Removal 11 Remove the Cylinder Block Assembly from the Pump NS To avoid the pistons from dropping out during Shaft Fig 30 removal of the assembly position fingers around the Cylinder in order to apply even pressure to all five pis tons Fig 32 Piston Cylinder Fig 32 Finger Placement During Removal A During separation be careful not to damage Fig 30 Cylinder Block Removal from Pump Shaft contact surfaces of Center Case and Cylinder Blocks Fig 33 12 Inspect each component of the Pump Cylinder Block As Alignment Pin Machined Surface sembly for burrs scoring pitting discoloration distor tion and wear Fig 31 A Machined Surface Cylinder Block Piston Spring lt Piston Snap Ring p Fig 31 Cylinder Block Remo
32. m the Brake Rod see arrow and remove Washer Fig 44 4 Disengage the Brake Rod from Brake Arm A see arrow and remove the Brake Rod Fig 44 5 Remove Brake Arm 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 Q Remove and discard O rings on Shafts Replace with new O rings before reassembly Refer to the As sembly section for further information NN 6 an TT i gt 2 S 0 Fulcrum Ne 0 Brake Return Spring Brake Arm A Torsion Spring Bypass Rod Fig 45 Bypass Shaft and Spring Q Inspect all Levers and Linkage for scoring pit ting discoloration or any other visual damaged Re place as necessary The Torsion Spring shown here disassembled for clarity only should be handled removing and installing as a sin gle item For assembly refer to Control Shaft amp Fulcrum Assembly on page 21 Control Shaft Brake Rod Fig 44 Levers and Linkage Removal 16 Tuff Torq K6 Hydrostatic Transaxle K61 Hydraulic Flow Diagram Forward Travel 10 cc rev e y H P R i E E 30 Micron S Filter gt S
33. mbly s ssesssesseesserssesssesseesssesssessersseossesseesse 27 Cylinder Block Pump Assemblvy 24 Differential Gear Assembly e e Le 30 Lower and Upper Case Assembly 33 Motor Shaft Center Case Assembly 28 Motor Shaft Assembly ss sssessseesssesssessseessseesssesssessseesssessseesse 25 Oil Change Frequency ssesesesseesserssesssesseeessesssessersseessesseesse 37 Oil Reguireme N nM re NM MEDE M M 2Q 37 Final Pinon Shaft Assembly ueee eee 32 Post Assembly Procedure sssesssesssesseesssesseesseessesssesseessee 36 Pump Shaft Assembly es ssseesssesssessseesssesssecssseesseesssessseesseess 22 Swash Plate ASSEMDIY cecscsssssesecsssssecssessssessesssseseeseens 24 Troubleshooting and Diagnosis Guides 38 Ordering Replacement Parts Online W W W Ze TUFF TORA ABOUT US PRODUCTS MARKETS INAOVATIONS NEWS SERVICE CONTACT Quality Engineering and Pric bak o k TUN T othe a iy en m Wi r 1 C L han T EARRAN sin Fatin vz BIB based upan fra Engin weng a chy se prncole l9 ony omer ser e Browse tr me r Anin nedan wi i CELE PODKAC E ate ein CLC tpege 12 wad DRIVING YOUR BEST IDEAS Home ABOUT US PRODUCTS amp MARKETS INNOVATIONS NEWS SERVICE CONTACT Online Ordering Meeting the Needs of
34. n and remove the 3 8 mm bolts washers 12mm wrench and detach the Brake Assembly Fig 2 Remove Snap Ring Snap Ring Pliers and the Brake Drum from Brake Shaft Fig 2 Brake Rod Assembly 3 gt Washer Cotter Pin Bolt amp Washer Brake Band Assembly Bolt amp Washer Bolt amp Washer Fig 2 Brake Assembly Removal Q Inspect all brake components for wear or dam age Replace as necessary Q Brake drum and brake band are to be free from oil and dust Shock Absorber and Control Arms Removal On K61 Models where applicable Control Lever H Control Arm 1 Remove the Shock Absorber Fig 3 with Roll Pin 2 Remove the Roll Pin and the H Control Arm from the oa h f rake Coniro rm Control Shaft Fig 4 an Enea 3 Remove the Roll Pin and the Brake Arm from the Brake Brake Arm B Shaft Fig 4 with Roll Pin 4 Remove the Roll Pin and Brake Arm B from Brake Arm S25 A Fig 4 7 5 Remove the Roll Pin and the Tow Release Valve Arm from the Bypass Shaft Fig 4 Release Valve Tow Arm with Roll Pin Fig 4 Arms and Roll Pins Control Lever H Control Arm Release Valve Tow Arm Shock Absorber BESE A V Sb mom ORS Lower Case Fig 3 Levers and Arms Removal 2 Tuff Torq K6 Hydrostatic Transaxle Lower Case Removal Filter Removal 1 Place the Transaxle on a Service Stand in the serviceable 1 Remove the
35. ng pitting discoloration distortion and wear Cylinder Block Piston Spring Piston vm Fig 25 Cylinder Block Assembly Q If any of the components of Cylinder Block As sembly are damaged they must be replaced with a complete Cylinder Block Assembly Individual compo nents are not serviced separately A Be careful that the Pistons do not fall out of Cylinder Block Do not set Cylinder Block down with mating surface contacting table top as this can cause damage to the machined surfaces Piston Cylinder Fig 26 Finger placement during removal Q 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 Motor Housing Removal 6 Remove the Spring and Snap Ring Next remove the Thrust Bearing Set seated in the Motor Housing Fig 27 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 Remove the Snap Ring and Seal Discard the Seal and replace it with a new Seal during reassembly Fig 27 Thrust Bearing Snap Ring Motor Housing Motor Shaft Fig 27 Motor Shaft and Housing Washer Snap Ring Motor Shaft Tuff Torq K6 Hydrostatic Transaxle Motor Shaft Removal 9 W
36. ng a 12 mm wrench the 3 Bolts 2 3 3 0 kg m 22 6 29 5 N m 17 21 ft Ibs Tightening torque 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 Brake Dru Snap Ring Tuff Torq K6 Hydrostatic Transaxle If Applicable Connect one end of the Shock Absorber to the Control Arm and the opposite end to the stud on Upper Case using the appropriate hardware i e Soring Clips or Cotter Pin Fig 49 Brake Rod RE TS Cotter Pin s Washer Engagement Lever Brake Band Brake Drum Assembly Snap Ring Fig 48 Brake Band Assembly Brake Arm Brake Rod Assembly ZA lt l2 Dn Brake Band Assembly Fig 49 Brake Band Installation 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 level reaches the top of the f ll port K61E Only Z Place Cap Sleeve amp Hose Clamp over the fill port Fig 50 Clamp e Acie Cap eeve w Se Fig 50 Oil Port Cap During the warranty period the serial number of the Transaxle is required when applying for reimbursement of appropriate repairs Serial number is also beneficial to the dealer in providing the prope
37. o the Pump Shaft if required Lubricate Bearing with clean oil old or new 3 Installation involving a new Bearing Fig 18 Seat Snap Ring in the Pump Shafts groove e Install Washer Press Bearing into position e Install Washer Seat Snap Ring in the Pump Shafts groove Seal Snap Ring Snap Ring Washer Snap Ring Fig 18 Pump Shaft Assembly Tuff Torq K6 Hydrostatic Transaxle Pump Shaft Assembly continued 4 Insert the Pump Shaft Assembly into the Upper Case Fig 19 5 Install Internal Snap Ring 6 Install a new Seal Q NET Apply a light coating of grease to the surface To avoid possible damage to the Seal lip during of all Seals and O rings Also apply a small amount of installation cover the splines of the Pump Shaft with grease around the mating hole of the Upper Case For tape Bearings and other machined parts apply a coating of oil Fig 19 Pump Shaft Assembly 23 Swash Plate Assembly 1 Install Thrust Metals into the Upper Case forming a 1 cradle for the Swash Plate Fig 20 5 2 Install the Thrust Bearing Group into the Swash Plate Comprising of 2 Thrust Plates and 1 Thrust 3 Bearing the Thrust Bearing Group should be oiled and A placed into the Swash Plate Starting with the thin Thrust Plate followed by the Thrust Bearing and finally the thick Thrust Plate Fig 20 3 If not previously done a
38. olding the ter Case remove the Magnet Clean the Magnet thor Center Case to the Upper Case place one hand over oughly before reassembling Fig 27 the Motor Housing and the other hand over the Cen ter Case While compressing both portions together Slightly lift the entire assembly from the Upper Case Fig 22 Center Case Cylinder Block Assembly Bolt 10 mm Center Case Motor Housing Motor Shaft Seal Fig 21 Magnet Removal Fig 22 Center Case and Motor Shaft Assemblies 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 from the Motor Shaft Assembly Fig 23 Center Case Cylinder Block Assembly Fig 23 Center Case and Motor Shaft Assembly A During separation be careful not to damage contact surfaces of Center Case and Cylinder Blocks Fig 24 Center Case Cylinder Block Assembly Machined Surfaces Fig 24 Center Case and Cylinder Block Machined Surfaces Q Inspect the machined surfaces of the Center Case If excessive scratches are detected replace the Center Case and both Cylinder Block Assemblies si multaneously 10 Cylinder Block Motor Assembly Removal 4 Remove the Cylinder Block Assembly from the Motor Shaft Fig 25 Inspect each component of the Cylinder Block Assembly for burrs scori
39. orq we offer our customers quality products at a modest price A manufacturer of hydrostatic and gear drive transmissions for the power equipment industry Tuff Torq offers a complete line of transmissions and parts to help fit your needs Designed to meet the needs of our OEM custom ers this website is designed to assist service and re pair facilities in locating and ordering parts for Tuff Torq manufactured transmissions It also provides transaxle parts identification troubleshooting guides online ordering capabilities as well as providing you with a complete inventory of parts service and same day shipping If you are a registered user please login from the Welcome Page to access the parts ordering system If you are not a OEM customer or authorized service distributor you may need to contact your equipment manufacturer or authorized dealer Select your brand from the Welcome page and you will be directed to the appropriate web site Navigating the website To access Tuff Torq s website type in www tufftorg com from your Internet browser From the Home page click on Service to enter the Online Ordering page Ref Page 1 From The Online Ordering page click on Click here to enter service website to enter the Welcome page Ref Page 2 From the Welcome page login for register users and follow the on screen instructions Or click on Catalog Order to enter Store Browser Ref Page
40. pply 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 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 Thrust Plate Thick Thrust Bearing Thrust Plate Thin Swash Plate A 0 gt ANTY A ace v X lt S Shift Blocks Fig 20 Pump Shaft Assembly 6 Using feeler gauge check the distance between the Swash Plate and the Shift Blocks 0 01 0 17 mm 0003 004 in Clearance should be 24 Cylinder Block Pump Assembly Apply a coating of oil to each of the Pistons Fig 21 Place the 5 Washers Springs and Pistons into the Cyl inder Block Fig 21 Install Snap Ring and Spring onto Pump Shaft Fig 22 Install Cylinder Block Assembly onto Pump Shaft Fig 24 Piston Washer Spring Fig 22 Cylinder Block Assembly Tuff Torq K6 Hydrostatic Transaxle Motor Shaft Assembly 1 Install a new Bearing onto the Motor Shaft if required A Be careful that the Pistons do not fall out of Cyl 2 Lubricate Bearing with clean oil old or new inder Block Damage to any component
41. prised of several internal Alignment Pin Machined Surfa parts Sleeve Assembly that are not serviced separately NP Other unserviceable parts include the Push Pins Springs NT and Valves Although these parts are also considered Machined Surface to be internal they will unlike the Sleeve Ass y eject pe NP during handling So great care should be taken not to lt gt lets components get away during the handling of the Center Case Fig 29 A Care should be taken when handling the Cen ter Case Assembly Any damage to its machined sur faces or internal components will result in the necessity N to replace the entire assembly Fig 29 31 Center Case Assembly e 2 Shaft Bushings a 2 Alignment Pins 2 Push Pin Assemblies 2 Sleeve Assemblies 2 2 Sleeve Assembly Not Illustrated Center Case ees NL 2 Pin Holders Fig 30 Center Case Machined Surfaces e 2 Ball Holders e 2 Balls 2 Back Up Rings e Sleeve A1 with orifice 2 2 Ball Springs A If Sleeves are removed it is important that the Sleeve with the orifice be reinstalled in the same valve ee port it was removed from Failure to install Sleeves in Sleeve A2 their correct location will result in the improper opera tion of the Transaxle Fig 37 Push Pin Center Case HOOO Center Case Assembly Sleeve Orifice Fig 31 Center Case Sleeve Placement Q To avoid possible damage
42. r parts for the series transaxle being repaired See page ii for Serial Number location Purging Air from Hydrostate Oil Circuit 2 Check oil level Place vehicle s drive axle on jack stands with wheels off floor Start engine and operate at low idle Repeat opening and closing of bypass valve while alter nately depressing forward and reverse pedals When vehicle starts to move increase engine speed to high idle Repeat quick starts and panic stops until transaxle gives full response Recheck and top off oil level Q For immediate air bleeding fill transmission s Center Case with new oil into the connector port in Center Case through connector hole of transaxle s Lower Case while rotating Motor Shaft by hand via the Brake Drum Refer to Fig 47 Adjusting Neutral iF 2 Complete air bleeding on the Transaxle Place the tractor s rear axle on a jack stands with wheels off the floor Remove necessary components from vehicle to access brass colored Fulcrum on Transaxle for adjustment Start engine and adjust the throttle for high idle speed full throttle Turn the Fulcrum Shaft clockwise until the Axle Shafts rotate in reverse Mark the top of the Fulcrum Turn the Fulcrum Shaft counterclockwise slowly un til the Axle Shafts stop rotating in reverse Mark the Transaxle Case Fig 51 Turn the Fulcrum Shaft counterclockwise slowly until the Axle Shafts rotate forward Turn the Ful
43. se Fig 9 from its seated position Separate the assembly Bear ing Bushing Washer Final Pinon Shaft and Reduction Fig 10 11 Push Pin 2 Inspect the Final Pinion Shaft and the Reduction Gear Center Case Assembly for scoring pitting discoloration and chipped or broken teeth Fig 11 Bearing Final Pinion Shaft Reduction Gear VDO Washer Fig 9 Push Pin and Bypass Valve Removal Fig I Final Pinion Assembly Q Final Pinion Assembly Removal Carefully inspect all parts for wear or damage l Replace as necessary Bearing OF Final Pinion Shaft eee MCS S Reduction Gear Bushing Fig 10 Final Pinon Assembly Removal 4 Tuff Torq K6 Hydrostatic Transaxle Final Pinion Shaft and Bushing Tolerances 1 Using calipers digital recommended measure the O D 2 Measure the I D Y of the loose Bushing Fig 12 X of the Final Pinion Shaft Fig 12 3 If the clearance Y X is gt 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 gt the wear limit of 0 50 mm replacement is necessary Fig 2 Final Pinion Shaft and Loose B
44. sponding grooves in Upper Case then push Axle Shafts through Bushings Q Install Bushings with the flat surfaces perpen dicular to the surface of the Upper Case Fig 39 Right Axle N Bushing Seal Fig 39 Axle Bushing Assembly 30 Tuff Torq K6 Hydrostatic Transaxle Axle Shafts and Differential Gear Assembly continued 4 Install the Differential Gear Assembly to the Left and Right Axle Shafts Fig 40 41 5 Install the 2 C Rings onto the Left and Right Axle Shafts then push Shafts inward until each C Ring is captured within the Side Gear s recess Fig 41 6 Install the 2 Thrust Washers to the Left and Right Axle Shafts Fig 41 Q 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 40 Differential Gear Assembly Axle Shaft Right Thrust Washer C Ring Differential Gear Assembly Upper Case ko Axle Shaft Left Fig 41 Differential Gear Installation 31 Final Pinon Shaft Assembly 1 Install Bearing onto Final Pinion Shaft Fig 42 Bearing 2 Install Final Shaft Gear Washer and Bushing onto Final Pinion Shaft Fig 42 3 Install Final Pinion Shaft Assembly
45. ssist you in the disassembly and reassembly of Transaxle AP 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 Black Electrical Tape Needle Nose Pliers O D Retaining Ring Pliers I D Retaining Ring Pliers Neoprene Hammer Ball Peen Hammer Telescoping Magnetic Pickup O lt N p Se 5 M Flathead Screw Driver Roll Pin Punch Feeler Gauge gt o N O Calipers Putty Knife WwW Wrench size 8 millimeter 12 millimeter 14 millimeter DC 17 millimeter Service Stand Part Number 1111 15 Sealant 16 17 18 19 Grease Filter Seal Kit s Oil 10W 30 Class CC or CD IV This manual is applicable for repair of all 9 K6 models built and distributed by Tuff Torg K6 C K6ID K61E K6IF K ll K6 J K6IM K6IN and K61O Serial Number Locations Serial Number Serial Number Specifications Transaxle Torque output 217 Ft Ibs Maximum Input Speed 3000 RPM Input Shaft SIZE eee eeee 14 85 mm 0 58 in Reduction Ratio Emm eenneee 18 79 1 or 26 97 1 Axle Shaft Size 25 4 mm 1 0 in Maximum Static Weight on Axle 265 kg 584 Ibs Weight Dry
46. t coating of grease to the surface of ing holes on the Upper Case then press into place the new O ring Also apply a small amount of grease 6 around the mating hole of Upper Case Rotate the Fulcrum until maximum distance is achieved between the Fulcrum head and the Control Shaft Spool Fig 15 Shift Block Kit Fig 13 Fulcrum Maximum Minimum Control Shaft Spool l Fulcrum Head Fig 15 Shift Blocks Fulcrum Assembly 21 Control Shaft amp Fulcrum Ass y continued 7 From the reverse side of the Upper Case Using a 17 mm wrench install washer and nut to the Fulcrum Fig 16 Tightening torque 2 5 3 3 kg m 24 6 32 5 N m 18 24 ft Ibs To adjust the Neutral Eccentric use a 8 mm wrench Fig 16 Fulcrum Assembly 8 Mount the Hydrostatic Control Arm onto the Control Shaft then align and secure with Roll Pin Fig 17 On some K61 models a Snap Ring must be installed on the Control Shaft before the OEM s Control Lever is installed Control Lever H Control Arm Fig 7 Hydrostatic Control Arm Assembly Q 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 22 Pump Shaft Assembly 1 Install a new Bearing ont
47. to the Push Pins Springs and or Bypass Valves these components should be installed after the Center Case has been se cured into the Upper Case To do otherwise could result in the items ejecting from valve causing their loss or damage Fig 29 Center Case Assembly NL Apply a light coating of oil to the Push Pins Valves Alignment Pins and the Machine surfaces of the Center Case Fig 29 30 27 Motor Shaft Center Case Assembly 1 Apply a film of clean oil to the machined surface of the 3 Install the Motor Shaft and Center Case assemblies into Center Case and to the mating surface of the Cylinder Upper Case as a single unit Fig 35 Block Fig 32 A 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 Center Case Cylinder Block Assembly 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 transaxle Align Seal Bearing and Motor Swash Plate Hous ing with Upper Case grooves Align the 2 Center Case Alignment Pins with Upper Case mounting holes as the Motor Shaft and Center Machined Surfaces Case Assemblies are squeezed together Verify that tab on bottom of Motor Housing slips into slot of Upper Fig 32 Machined Surfaces Center Case C
48. ushing Clearance Differential Gear Assembly Removal Axle Shaft Left Thrust Washer C Ring Differential Gear Assembly o M Upper Case k Axle Shaft Right Fig 13 Differential Gear Assembly and Axle Removal 5 Differential Gear Assembly Removal continued Axle Shaft Left Thrust Washer C Ring Differential Gear Assembly ZC haa Upper Case ko Axle Shaft Right Fig 14 Differential Gear Assembly and Axle Removal 1 Remove Thrust Washer from either the Left or Right Axle Ne Rotating the Axle until open end of C Ring is Fig 14 16 facing downward will prevent C Ring from dropping into Upper Case 2 After removing the Thrust Washer rotate the Axle until PP the open end of C Ring is facing downward Holding the 5 Carefully back out and remove the Left and Right Axle Differential Side Gear stationary slightly slide the Axle Shafts Fig 14 16 outward exposing the C Ring Using a Telescoping Mag net remove C Ring Fig 14 16 6 Remove 2 loose Bushings from the Upper Case Fig 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 Inspect the Axle Shafts and Bushings for scor Axle Shafts until the shafts splines clear the Side Gears ing pitting discoloration damaged ring grooves and Remove the Gear Assembly and inspect components for chipped or broken splines Replace as necessary
49. val Q If any of the components of the Cylinder Block Assembly are damaged the complete assembly must be replaced Individual components are not serviced separately Center Case Fig 33 Center Case Machined Surfaces Q Inspect the machined surfaces of the Center Case If excessive scratches are detected replace the Center Case and both Cylinder Block Assemblies si multaneously Fig 33 A Take care to insure that 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 12 Tuff Torq K6 Hydrostatic Transaxle Swash Plate Removal 1 Before removing the Swash Plate Assembly measure the 6 Remove the 2 Thrust Metals bearing pads from the clearance using Feeler gauge between edge of Swash Upper Case Fig 36 Plate s Slot and the Shift Blocks If the clearance gap is gt 0 15 mm 0 005 in replace both Shift Blocks and the Swash Plate Assembly simultaneously Fig 34 Thrust Plate Thick Thrust Bearing Thrust Plate Thin Swash Plate Thrust Metal Bearings Fig 36 Thrust Metal Bearing Removal Q Inspect Thrust Bearing components for pitting scoring discoloration missing rollers and roller retain er breakage Fig 34 Shift Blocks Clearance Tolerance 2 Remove the Spring and the Snap Ring Fig 35 Spring S Cylinder Block Assembly snap Min Cylinder Block Pump Sha
50. yl Blk Case Press down on Center Case until Alignment Pins are securely seated ui 2 Align the Motor Shaft with the bushing in the Center Case and press together Fig 33 8 A Pilot Hole on Center Case aids in the aligning of Center Case and the Pump Shaft A Care should be taken when handling the Cen 4 Install 2 10 mm Bolts and tighten with fingers Fig 34 ter Case to avoid any possibility of damage Also care should be taken while compressing pistons in the Cyl inder Block If pressure is relaxed during assembly the pistons may eject from the Cylinder Block Thus caus ing damage to the pistons and making it necessary to replace the entire assembly Center Case Cylinder Block Assembly Motor Housing Fig 34 Center Case Mounting Fig 33 Hydrostatic Motor Assembly 28 Tuff Torq K61 Hydrostatic Transaxle Motor Shaft Center Case Assembly continued Center Case and Motor Assembly Pilot Hole Z5 A 7 Align Alignment Pins to Upper Case A ee X lt LP gt Pump Cylinder Block Fig 35 Hydrostatic Pump and Motor Assembly 5 Install Magnet and Bolt in third hole of Center Case 4 Tighten the 3 10 mm Bolts 14 mm wrench evenly to Fig 36 draw Center Case Assembly into place Tightening torque 4 5 6 5 kg m 44 3 63 9 N m 33 47 ft Ibs 5 Install Push Pins Springs and Bypass Valves in Center Case then while depressing Push Pin Assemblies
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