Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 310-2200 EZT® Integrated Zero-Turn Transaxle Service and Repair Manual BLN-51856 December 2008 www.mymowerparts.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 TABLE OF CONTENTS Section Page Foreword ............................................................................................................................. 1 Description and Operation ................................................................................................ 2 Introduction ..........................................................................................................................................
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 FOREWORD Headquartered in Sullivan, Illinois, Hydro-Gear® is a world leader in the design, manufacture, and service of quality hydrostatic transaxles for the lawn and garden industry. The mission of our company is to be recognized by our customers and the industry as a world-class supplier and the quality leader in everything we do. Repair procedures require that the transaxle unit be removed from the vehicle.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 SECTION 1. DESCRIPTION AND OPERATION INTRODUCTION The purpose of this manual is to provide information useful in servicing the Hydro-Gear® Integrated Zero-Turn Transaxle (EZT®). This manual includes the EZT’s general descriptions, hydraulic schematics, technical specifications, servicing and troubleshooting procedures. The transaxle normally will not require servicing during the life of the vehicle in which it is installed.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 310-2200 EZT® HYDRAULIC FLOW SCHEMATIC Figure 2. Hydraulic Flow Illustration HYDRAULIC SCHEMATIC Figure 2 provides an illustration of the hydraulic oil circuit. The oil supply for the hydraulic system of the 310-2200 EZT® is also utilized for lubricating the components of the final drive assembly. The input shaft and pump cylinder block are turned in one direction only by the engine/drive belt/pulley combination.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 EXTERNAL FEATURES 310-2200 4 310-2200 EZT® www.mymowerparts.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 TECHNICAL SPECIFICATIONS Technical specifications for the 310-2200 EZT® are listed in Table 1. Table 1. Technical Specifications Input Speeds Maximum Tire Diameter Maximum: 3000 RPM Minimum: 1800 RPM 20 inch; 508 mm Weight of Unit Maximum Weight on Drive Tires 29.0 lbs. (13.15 Kg) 300 lbs. (136 Kg) with 20” Tires 340 lbs. (154 Kg) with 18” Tires Table 2.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 SECTION 2. SAFETY This symbol points out important safety instructions which, if not followed, could endanger the personal safety and/or property of yourself and others. Read and follow all instructions in this manual before attempting maintenance on your transaxle. When you see this symbol - HEED ITS WARNING.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 SECTION 3. TROUBLESHOOTING WARNING Do not attempt any servicing or adjustments with the engine running. Use extreme caution while inspecting the drive belt assembly and all vehicle linkage! Follow all safety procedures outlined in the vehicle owner’s manual.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 SECTION 4. SERVICE AND MAINTENANCE NOTE: Any servicing dealer attempting a warranty repair must have prior approval before conducting maintenance of a Hydro-Gear® product unless the servicing dealer is a current Authorized HydroGear Service Center. EXTERNAL MAINTENANCE Regular external maintenance of the 310-2200 EZT® should include the following: 1. Check the vehicle operator’s manual for the recommended load ratings.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 FLUID CHANGE FLUID CHANGE PROCEDURE This transaxle is factory filled, sealed and does not require oil maintenance. However, in the event of oil contamination or degradation, oil addition or change may alleviate certain performance problems. 1. Remove the transaxle from the vehicle. 2. Clean the oil fill port area of any debris. 5. Fill the transaxle at the oil fill port according to Figure 4. 6. Install the oil fill port fitting. 7.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 PURGING PROCEDURES Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that it is purged from the system. Before starting, make sure the transaxle/transmission is at the proper oil level. If it is not, fill to the specifications outlined on Page 9, Figure 4.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 RETURN TO NEUTRAL SETTING WARNING WARNING POTENTIAL FOR SERIOUS INJURY Do not attempt any servicing or adjustments with the engine running. Use extreme caution while inspecting the drive belt assembly and all vehicle linkage! Inattention to proper safety, operation, or maintenance procedures could result in personal injury, or damage to the equipment.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 NOTES 12 310-2200 EZT® www.mymowerparts.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 SECTION 5. REPAIR HOW TO USE THIS MANUAL Each subassembly illustrated in this section is illustrated with an exploded view showing the parts involved. The item reference numbers in each illustration are for assembly instructions only. See page 29 for part names and descriptions. A complete exploded view and item list of the transaxle is provided at the end of the repair section.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 TOOLS AND TORQUES Table 5. Required Tools Miscellaneous 310-2200 Service & Repair Manual Flat Blade Screw Driver (2) Torque Wrench Air Impact Wrench Rubber Mallet Breaker Bar Side Cutters/Snips Pliers Needle Nose Large External Snap Ring Small Internal Snap Ring Sockets 1/2”-3/8” Adapter 3/8” Deep 1/2” Deep 7/16” Deep 9/16” Deep 3/4” Deep 13/16” Deep 7/8” T-25 Torx Head T-40 Torx Head Apex AN-08 Table 6.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 CONTROL ARM AND BYPASS ARM Refer to Figure 6. Assembly Disassembly 1. Install the bypass arm (17) onto the bypass rod. Secure the bypass arm with a new retaining ring (18). 1. Loosen and remove the lock nut (26) and flat washer (24). Discard the lock nut (26) and flat washer (24). 2. Remove the torx head screw (25) from the directional control. 3. Remove control arm (23) and pucks (22). Discard the pucks. 4.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 SEAL KIT REPLACEMENT Before disassembly, wipe the unit free of any debris to avoid contamination. Refer to Figure 7. Input Seal 1. Remove the input pulley from the input shaft. 2. Remove the seal retaining ring (34). 3. Carefully pull the input seal (33) out of the housing bore with a “hook” type tool. Care must be taken to avoid damage to the housing bore or shaft sealing area. 4.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 COG BRAKE AND SIDE HOUSING 2. Check for excessive looseness at the arm pivot point. Refer to Figure 8. Disassembly 1. Remove the control arm and bypass arm. See page 15. 2. Remove the oil from the transaxle. See page 9. 3. Remove the brake arm assembly (55), retaining ring (14) and cog brake disc (100). 4. Remove the lip seal (10). 5. Remove the housing screws (9). 6.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 AXLE SHAFT, REDUCTION GEARS AND EXPANSION PLATE Refer to Figure 9. 3. Inspect the axle shaft, bearing and bushing. Disassembly 4. Inspect the expansion plate. 1. Remove the bypass arm and control arm. See page 15. Assembly 3. Remove the side housing. See page 17. 1. Apply a small bead of sealant to the expansion plate area of the housing. See page 27. Install the expansion plate (53). Torque the screws according to Table 6. 4.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 MOTOR SHAFT Refer to Figure 10. Assembly Disassembly 1. Insert the motor shaft (39) with the pinnion gear (38) and flat washers (36 & 40) into the center section (57). 1. Remove the control arm and bypass arm. See page 15. 2. Drain the oil from the transaxle. See page 9. 3. Remove the side housing. See page 17. 4. Remove the reduction gears. See page 18. 5. Remove flat washer (36), motor shaft and pinion gear (39 & 38) and flat washer (40).
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 INPUT SHAFT AND BYPASS ROD 5. Deburr the end of the bypass rod. Install the bypass rod (15), retaining ring (14), seal (13) and retaining ring (16). Refer to Figure 11. Disassembly 1. Remove the control arm and bypass arm. See page 15. 6. Install the motor shaft. See page 19. 2. Drain the oil from the transaxle. See page 9. 8. Install the side housing. See page 17. 3. Remove the side housing. See page 17. 4. Remove the reduction gears.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 HYDRAULIC COMPONENTS Refer to Figures 12-21. (Center Section/Filter) Disassembly 12. (See Figure 16) Remove the center section mounting screws (12). NOTE: The center section is under motor block piston spring pressure. These screws are factory installed to 700 lb-in (80 Nm) and use an anaerobic thread adhesive. A breaker bar will be required at this step. Clean the internal threads of the mounting holes with compressed air. 1.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 20. Remove the thrust bearing assembly (35) from the housing (1). Inspect the thrust bearing and thrust bearing cavity in the housing. Inspection 1. Inspect the pump cylinder block running surface for wear or damage. 2. Inspect the swashplate and thrust bearing assemblies for wear or damage. 3. Inspect the center section block running surfaces.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 locate. (Swashplate/Pump Block) 11. (See Figure 15) Install the pump thrust bearing (35) in the trunnion machined swashplate (19). NOTE: Place the thin race of the bearing towards the swashplate. The thick race must face the pistons. 12. (See Figure 13) Place the pump block assembly (4), pistons down, on top of the thrust bearing in the swashplate (19). 13. Coat the pump running surface with clean motor oil. 14.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 Figure 15. Figure 18. Figure 16. Figure 19. Figure 17. 24 310-2200 EZT® www.mymowerparts.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 TRANSAXLE INSTALLATION Use the following procedure to complete the installation of the transaxle on the vehicle. 1. Install and secure the transaxle on the vehicle according to the instructions in the vehicle owner’s manual. 2. With the vehicle raised, install the wheels on the axles, and snug the wheel hardware. 3. Lower the vehicle wheels to the ground and torque the wheel hardware per the vehicle owner’s manual. Figure 20. Figure 21.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 ASSEMBLY AFTER A COMPLETE TEARDOWN If the unit has been torn down completely, the following summary identifies the assembly procedures necessary to completely assemble the unit. Each assembly procedure is located by a page reference. 3. Install the axle shaft, reduction gears and expansion plate. See page 18.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 SEALANT APPLICATION NOTE: Prior to applying the new sealant, the old sealant must be removed from all surfaces. A small consistent bead of the sealant around the housing face will be sufficient. Use sparingly. The illustration below indicates the correct areas. 310-2200 EZT® 27 www.mymowerparts.
28 www.mymowerparts.com ITEMS NOT SHOWN 11 - OIL, 20W50 58 - SEALANT TUBE (10.3 oz) 52 - KIT, SEAL 145 - ASSEMBLY, HUB PULLER NOTES: 1. BRAKE AND CONTROL ARM CAN BE ON EITHER SIDE. 2. LH SIDE SHOWN. RH SIDE IS A MIRROR IMAGE. Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 310-2200 EXPLODED VIEW Figure 22.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 310-2200 ITEMS LIST No. 1 2 DESCRIPTION No. ASSEMBLY, MAIN HOUSING 47 DESCRIPTION WASHER, 3/4 ID X 1-1/2 OD X .13 HOUSING, MAIN 48 BEARING, SLEEVE (INBOARD) BUSHING, .865 X .985 X.790 49 AXLE PLATE, EXPANSION 50 BUSHING, .752 X 1.571 X .625 SCREW, 10-32 X 1/2 (SELF TAPPING) 51 SEAL, LIP .750 X 1.577 X .250 PIN, STANDARD, HEADLESS 52 KIT, SEAL SEAL, LIP .375 X .75 X .
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 GLOSSARY OF TERMS Axial Piston: Type of design for hydraulic motors and pumps in which the pistons are arranged parallel with the spindle (input or output shaft). Bantam Duty: A descriptive term relating to the product capacity (meaning: light duty). Bypass Valve: A valve whose primary function is to open a path for the fluid to bypass the motor or pump. Also referred to occasionally as the freewheel valve or dump valve.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 Hydrostatic Transmission: The combination of a hydraulic pump and motor in one housing to form a device for the control and transfer of power. Inlet Line: A supply line to the pump. Integrated Zero-Turn Transaxle: The combination of a hydrostatic transmission and gear case in one housing to form a complete transaxle. Manifold: A conductor which provides multiple connection ports.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 NOTES 32 310-2200 EZT® www.mymowerparts.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 NOTES 310-2200 EZT® 33 www.mymowerparts.
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983 © 2008 Hydro-Gear Rev. P2 Printed in U.S.A. 34 310-2200 EZT® www.mymowerparts.
