Husqvarna Tuff Torq K61 Service Manual
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Husqvarna Tuff Torq K61 Service Manual

Husqvarna Tuff Torq K61 Service Manual

Hydrostatic transaxle
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Summary of Contents for Husqvarna Tuff Torq K61

  • Page 2: Table Of Contents

    T a b l e C o n t e n t s Ordering Replacement Parts Online .........ii Adjusting Neutral ..............36 Icons Used in this Manual .............iv Axle Shafts and Differential Gear Assembly ....30 Recommended Tools and Equipment ......iv Before Starting Assembly .............18 Serial Number Locations ............iv Bleeding Air from Hydrostate Oil Circuit ......36 Specifications: ................iv...

  • Page 3: Icons Used In This Manual

    Icons Used in this Manual 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 This symbol identifies the presents of IMPOR- K61O TANT, if not critical, information. Serial Number Locations This symbol is intended to alert you of important technical information and/or maintenance procedures...

  • Page 4: Disassembly Of Transaxle

    Tuff Torq K61 Hydrostatic Transaxle Disassembly of Transaxle Drain Oil Brake Assembly Removal Remove the Cotter Pin and Washer from the Brake Rod Assembly. (Fig. 2) Before beginning tear-down clean work area Remove the Brake Rod Assembly from Brake Arm B (see thoroughly and cover workbench with clean paper.

  • Page 5: Shock Absorber And Control Arms Removal

    Shock Absorber and Control Arms Removal (On K61 Models where applicable) Remove the Shock Absorber. (Fig. 3) Remove the Roll Pin and the H-Control Arm from the Control Shaft. (Fig. 4) Remove the Roll Pin and the Brake Arm from the Brake Shaft.

  • Page 6: C" Arm Removal

    Tuff Torq K61 Hydrostatic Transaxle Lower Case Removal Filter Removal Place the Transaxle on a Service Stand in the serviceable Remove the Filter from the Center Case and discard. position (Lower Case up), to keep it steady during tear- (Fig. 7) down.

  • Page 7: Bypass Valve Removal

    Bypass Valve Removal Final Pinon Assembly Remove (2) Push Pins, Springs, and Bypass Valve from Remove the Final Pinion Assembly from the Upper Case the Center Case. (Fig. 9) from its seated position. Separate the assembly, Bear- ing, Bushing, Washer, Final Pinon Shaft, and Reduction. (Fig.

  • Page 8: Differential Gear Assembly Removal

    Tuff Torq K61 Hydrostatic Transaxle Final Pinion Shaft and Bushing Tolerances Measure the I. D. (Y) of the “loose” Bushing. (Fig. 12) Using calipers (digital recommended) measure the O. D. (X) of the Final Pinion Shaft. (Fig. 12) If the clearance (Y-X) is > 0.50 mm (.019 in), replace the Final Pinion Shaft and/or Bushing.
  • Page 9 Differential Gear Assembly Removal (continued) Fig 14, Differential Gear Assembly and Axle Removal Remove Thrust Washer from either the Left or Right Axle. Rotating the Axle until open end of C-Ring is facing downward will prevent C-Ring from dropping into (Fig.

  • Page 10: Axel Shafts And Differential Gear Assemblies

    Tuff Torq K61 Hydrostatic Transaxle Axle Shaft and Bushing Tolerances Measure the I. D. (Y) of the “Loose” Bushing. (Fig. 15) Using calipers (digital recommended) measure the O. D. (X) of the Axle Shaft. (Fig. 15) If the clearance (Y-X) is > 0.35 mm (0.014 in), replace the Axle Shaft and/or “loose”...

  • Page 11: Axle Seal Removal

    Differential Gear Assembly Removal Axle Seal Removal Remove the Differential Side Gears, Thrust Washers, Dif- 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.

  • Page 12: Center Case & Motor Shaft Ass'y Removal

    Tuff Torq K61 Hydrostatic Transaxle Hydrostatic Pump Removal Slide the Brake Drum onto the Motor Shaft to provide a means of grip- ing and lifting the Center Case and Mo- tor Shaft Assemblies from the Upper Case. Fig. 20, Center Case and Motor Shaft Assemblies Center Case &...

  • Page 13: Center Case Removal

    Hydrostatic Pump Removal (continued) Center Case Removal Cylinder Block (Motor) Assembly Removal While still maintaining pressure on the Cylinder Block Remove the Cylinder Block Assembly from the Motor Assembly and the Motor Housing, carefully separate the Shaft. (Fig. 25) Center Case from the Motor Shaft Assembly. (Fig. 23) Inspect each component of the Cylinder Block Assembly for burrs, scoring, pitting, discoloration, distortion, and wear.

  • Page 14: Motor Shaft Removal

    Tuff Torq K61 Hydrostatic Transaxle Hydrostatic Pump Removal (continued) Motor Housing Removal Motor Shaft Removal Remove the Spring and Snap Ring. Next, remove the Withdraw the Motor Shaft from the Motor Housing. If Thrust Bearing Set seated in the Motor Housing. (Fig. 27) the Shaft doesn’t back out freely, check to see if Snap...

  • Page 15: Cylinder Block Assembly (Pump) Removal

    Hydrostatic Pump Removal (continued) Cylinder Block Assembly (Pump) Removal 11. Remove the Cylinder Block Assembly from the Pump 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.

  • Page 16: Swash Plate Removal

    Tuff Torq K61 Hydrostatic Transaxle Swash Plate Removal Remove the (2) Thrust Metals (bearing pads) from the Before removing the Swash Plate Assembly measure the Upper Case. (Fig. 36) clearance (using Feeler gauge) between edge of Swash Plate’s Slot and the Shift Blocks. If the clearance (gap) is >...

  • Page 17: Fulcrum Removal

    Swash Plate Removal (continued) Fulcrum Removal Remove the Nut (17mm) and Washer from the Fulcrum (Neutral Adjust Eccentric). (Fig. 40) Fig. 38, Swash Plate’s Machined Ramps Inspect the Swash Plate’s machined ramp sur- Fig. 40, Fulcrum Removal, from top of Upper Case faces and Press-Fit Bushings for scoring, pitting, dis- coloration, and wear.

  • Page 18: Pump Shaft Removal

    Tuff Torq K61 Hydrostatic Transaxle Pump Shaft Removal 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) Inspect the Shaft and its components for scor- ing, pitting, discoloration, and other wear.

  • Page 19: Levers (Shafts) And Linkage Removal

    Levers (Shafts) and Linkage Removal (If Applicable) Remove the Control Shaft Assembly. Remove the Fulcrum. Refer to page 14 for more details. ➊ Disconnect Snap Pin from the Brake Rod (see arrow and remove Washer. (Fig. 44) Disengage the Brake Rod from Brake Arm “A” (see arrow ➋...

  • Page 20: Hydraulic Flow Diagram

    Tuff Torq K61 Hydrostatic Transaxle Hydraulic Flow Diagram...

  • Page 21: Assembly Of Transaxle

    Assembly 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 Rather than lubricating packing items (O-rings debris, this includes your work area and tools. and Seals) in advance, apply a light coating of grease Have on hand a new Seal Kit (19215499150).
  • Page 22 Tuff Torq K61 Hydrostatic Transaxle Interlock Linkage (If Applicable) Place the Upper Case back to the Service Position; then, attach the Bypass Rod to the Bypass Shaft. (Fig. 3) Fig. 5, Brake Shaft & Return Spring Assembly Fig. 3, Bypass Rod Assembly Brake Shaft Assembly (If Applicable) Install a new O-ring onto the Brake Shaft.
  • Page 23 Brake Arm “A” Assembly From the reverse side of the Upper Case, mount the Install a new O-ring onto the Brake Arm. (Fig. 8) Brake Arm onto the Brake Shaft. The side of the Brake Attach the Brake Rod to the Brake Arm; then, to the Arm with the word “UP”...
  • Page 24 Tuff Torq K61 Hydrostatic Transaxle Control Shaft & Fulcrum Assembly Place the head of the Fulcrum between the legs of the Install a new O-ring onto the Control Shaft. (Fig. 12) Torsion Spring. (Fig. 14 ) Apply a light coating of grease to the surface of the new O-ring.

  • Page 25: Pump Shaft Assembly

    Control Shaft & Fulcrum Ass’y (continued) Pump Shaft Assembly From the reverse side of the Upper Case; Using a 17 mm Install a new Bearing onto the Pump Shaft, if required. wrench, install washer and nut to the Fulcrum. (Fig. 16) Lubricate Bearing with clean oil, (old or new).
  • Page 26 Tuff Torq K61 Hydrostatic Transaxle Pump Shaft Assembly (continued) Insert the Pump Shaft Assembly into the Upper Case. (Fig. 19) Install Internal Snap Ring. Install a new Seal. Apply a light coating of grease to the surface To avoid possible damage to the Seal lip, during of all Seals and O-rings.

  • Page 27: Cylinder Block (Pump) Assembly

    Swash Plate Assembly Cylinder Block (Pump) Assembly Install Thrust Metals into the Upper Case (forming a Apply a coating of oil to each of the Pistons. (Fig. 21) cradle for the Swash Plate). (Fig. 20) Place the (5) Washers, Springs and Pistons into the Cyl- Install the Thrust Bearing Group into the Swash Plate.

  • Page 28: Motor Shaft Assembly

    Tuff Torq K61 Hydrostatic Transaxle Motor Shaft Assembly Install a new Bearing onto the Motor Shaft, if required. Be careful that the Pistons do not fall out of Cyl- Lubricate Bearing with clean oil, (old or new). inder Block. Damage to any component of the assembly Installation involving a new Bearing: (Fig.
  • Page 29 Motor Shaft Assembly (continued) 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 Bearing and finally, the “thick”...

  • Page 30: Center Case Assembly

    Tuff Torq K61 Hydrostatic Transaxle Center Case Assembly The Center Case Assembly is comprised of several internal parts (Sleeve Assembly) that are not serviced separately. Other unserviceable parts include the Push Pins, Springs and Valves. Although, these parts are also considered to be internal, they will, unlike the Sleeve Ass’y, eject...

  • Page 31: Motor Shaft/Center Case Assembly

    Motor Shaft/Center Case Assembly Install the Motor Shaft and Center Case assemblies into Apply a film of clean oil to the machined surface of the Upper Case as a single unit. (Fig. 35) Center Case and to the mating surface of the Cylinder Block.
  • Page 32 Tuff Torq K61 Hydrostatic Transaxle Motor Shaft/Center Case Assembly (continued) Fig. 35, Hydrostatic Pump and Motor Assembly Install Magnet and Bolt in third hole of Center Case. Tighten the (3) 10 mm Bolts (14 mm wrench) evenly to (Fig. 36) draw Center Case Assembly into place.

  • Page 33: Axle Shafts And Differential Gear Assembly

    Differential Gear Assembly Axle Shafts and Differential Gear Assembly Install the (2) Differential Pinion Gears to Differential Place new Seals onto Left and Right Axle Shafts. Pinion Shaft. (Fig. 38) (Fig. 39) Install the Differential Pinion Assembly (Pinion Shaft and (2) Pinion Gears) within the Final Gear.
  • Page 34 Tuff Torq K61 Hydrostatic Transaxle Axle Shafts and Differential Gear Assembly (continued) Install the Differential Gear Assembly to the Left and Right Axle Shafts. (Fig. 40, 41) 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.

  • Page 35: Final Pinon Shaft Assembly

    Final Pinon Shaft Assembly Install Bearing onto Final Pinion Shaft. (Fig. 42) Install Final Shaft Gear, Washer and Bushing onto Final Pinion Shaft. (Fig. 42) Install Final Pinion Shaft Assembly into Upper Case. (Fig. 43) Install Bushing with flat surface parallel to the surface of the Upper Case.

  • Page 36: Lower And Upper Case Assembly

    Tuff Torq K61 Hydrostatic Transaxle Lower and Upper Case Assembly Apply a thin even bead of sealant to mating surface of Place a new Filter over groove of Center Case. Lower Case, following along the inside surface of bolt holes — Be sure to apply sealant aroung center bolt hole.
  • Page 37 Lower and Upper Case Ass’y (continued) Install Oil Drain Plug (12 mm wrench) with new Seal Install (1) M8x75 Bolt (arrow 14), (2) M8x40 Bolts (ar- Washer into Lower Case. rows 8 & 10) and (11) M8x30 Bolts (arrows 1–13) to Lower Case/Upper Case.

  • Page 38: Brake Assembly

    Tuff Torq K61 Hydrostatic Transaxle Brake Assembly (If Applicable) Connect one end of the Shock Absorber Install the Brake Drum and Snap Ring onto Motor Shaft. to the Control Arm and the opposite end to the stud on (Fig. 49) Upper Case, using the appropriate hardware, i.e., Spring...

  • Page 39: Adjusting Neutral

    Post Assembly Procedures Pour new SAE 10W30, Class CC or CD engine oil, approx. 2.5 L (2.65 qt.), into the Transaxle until oil level reaches For immediate air bleeding, fill transmission’s the top of the fill port. Center Case with new oil into the connector port in K61E Only: Center Case through connector hole of transaxle’s Lower Case while rotating Motor Shaft by hand via the...

  • Page 40: Oil Change Frequency

    Tuff Torq K61 Hydrostatic Transaxle Oil Change Frequency For consumer use in yard tractor and riding mower appli- cations oil changing is not emphasized as most hom- eowners are not equipped or in the habit of changing transmission oil. For most consumers, the transaxle will outlast the life of the vehicle.

  • Page 41: Troubleshooting And Diagnosis Guides

    Troubleshooting and Diagnosis Guides 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 Note: If your specific problem and/or solution is not listed below, consult a qualified Tuff Torq Distributor.
  • Page 42 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 Brakes Malfunction BRAKE LINKAGE BROKEN, BENT, BINDING, OR DIS- CLEAN AND INSPECT TRANSAXLE FOR ACCUMULAT- ◆...
  • Page 43 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 Hard Shifting SPEED (SHIFT) CONTROL LINKAGE BELT, BINDING REMOVE ACCUMULATED DEBRIS - REPAIR OR RE- ◆...
  • Page 44 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 Oil Leakage (continued) REPLACE SEALS AND O-RINGS AS REQUIRED CASE HALVES IF TORQUE MEETS SPECIFICATIONS ◆...
  • Page 45 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 No Drive (continued) ◆ BY-PASS (TOW) VALVE ACTIVATED CHECK BY-PASS (TOW) VALVE CONTROL FOR BENT, ◆...
  • Page 46 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 Slows Down Under Heavy Load... High Operating Temperature...“Stall” Condition CHECK OIL LEVEL IN EXPANSION TANK - SAE 10W30 INCORRECT OIL/OIL LEVEL IN TRANSAXLE ◆...
  • Page 47 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 Lower Power - Both Directions (continued) CHECK BY-PASS (TOW) VALVE CONTROL FOR BENT, BY-PASS (TOW) VALVE PARTIALLY ACTIVATED ◆...
  • Page 48 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 By-Pass (Tow) Valve Does Not Operate Correctly ACCUMULATION OF GRASS AND/OR OTHER DEBRIS CLEAN TRANSAXLE/TRACTOR OF ACCUMULATED ◆...

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