HYDRO-GEAR 310-0510 INTEGRATED HYDROSTATIC TRANSAXLE MANUAL Table of Contents – Page 1 of 1 FOREWORD SECTION 1 DESCRIPTION AND OPERATION INTRODUCTION GENERAL DESCRIPTION HYDRAULIC SCHEMATIC EXTERNAL FEATURES 310-0510 MODEL RECOGNITION TECHNICAL SPECIFICATIONS PRODUCT IDENTIFICATION SECTION 2 SAFETY PERSONAL SAFETY TOOL SAFETY WORK AREA SAFETY SERVICING SAFETY SECTION 3 TROUBLESHOOTING SECTION 4 SERVICE AND MAINTENANCE EXTERNAL MAINTENANCE SERVICE AND MAINTENANCE PROCEDURES FLUIDS FLUID CHANGE PURGING PROCED
We set the wheels in motion.
Table of Contents Section Page Foreword ........................................................................................................................................ 1 Section 1 Description and Operation ........................................................................................... 2 Introduction ........................................................................................................................................................ 2 General Description..............
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. tools and the mechanics be supplied with the latest information available. All repair procedures illustrated in this guide are suggested, but preferred methods of repair.
SECTION 1. DESCRIPTION AND OPERATION INTRODUCTION The purpose of this manual is to provide information useful in servicing the Hydro-Gear Integrated Hydrostatic Transaxle (IHT). This manual includes the IHT’s general description, hydraulic schematic, technical specifications, servicing and troubleshooting procedures. The transaxle normally will not require servicing during the life of the vehicle in which it is installed.
INPUT SHAFT VARIABLE SWASH PLATE CYLINDER BLOCK ASSEMBLY CYLINDER BLOCK ASSEMBLY 10 CC VARIABLE 10 CC FIXED DISPLACEMENT MOTOR DISPLACEMENT PUMP CHECK VALVE BYPASS ACTUATOR FIXED DISPLACEMENT ANGLE CHECK VALVE FILTER ASSEMBLY RESERVOIR TRANSAXLE HOUSING DIFFERENTIAL ASSEMBLY Figure 2. 310-0510 Hydraulic Flow Illustration HYDRAULIC SCHEMATIC Figure 2 provides an illustration of the hydraulic oil circuit.
EXTERNAL FEATURES 310-0510 FAN FRICTION PACK BELT KEEPER CONTROL ARM BRAKE ARM BRAKE DISC ADJUSTING PUCK BYPASS ARM Return to Neutral Option Friction Pack Option AXLE CLIP FILL PORT AXLE CLIP EXPANSION TANK AXLE SHAFT INPUT SHAFT AXLE CLIP AXLE CLIP 4 310-0510 IHT
MODEL RECOGNITION 618-0319 173839 310-0510 IHT 166768 104-1760 036932 618-0389A 5
TECHNICAL SPECIFICATIONS Technical specifications for the 310-0510 IHT are listed in Table 1. Table 1. 310-0510 Technical Specifications Overall Transaxle Reduction 22.15:1 Axle Shaft Options Type: Keyed / Double “D” Diameter: 0.75 inch; 19.05 mm Input Speeds Maximum: 3000 RPM Minimum: 1800 RPM Brake Type Disc Maximum Tire Diameter 20 inch; 508 mm Weight of Unit 30 lb; 14 kg PRODUCT IDENTIFICATION The model and configuration of the 310-0510 IHT can be determined from the label shown in Figure 3.
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. Wear appropriate clothing. Loose or hanging clothing or jewelry can be hazardous. Use the appropriate safety equipment, such as eye and hearing protection, and safety-toe and slipproof shoes.
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! In many cases problems with the 310-0510 are not related to a defective transaxle, but are caused by slipping drive belts, partially engaged bypass valves, and loose or damaged control linkages.
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 Hydro-Gear Service Center. EXTERNAL MAINTENANCE Regular external maintenance of the 310-0510 IHT should include the following: 1. Check the vehicle operator’s manual for the recommended load ratings. Insure the current application does not exceed load rating.
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. 8. Install the tank support bracket and self tapping bolt making sure not to cross thread the bolt. Torque the bolt to the lower value of the torque specification listed in Table 5. 9. Fill the transaxle at the oil fill port according to Figure 4. 1.
PURGING PROCEDURES Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that it be purged from the system. These purge procedures should be implemented any time a hydrostatic system has been opened to facilitate maintenance or any additional oil has been added to the system. Air creates inefficiency because its compression and expansion rate is higher than that of the oil approved for use in hydrostatic drive systems.
RETURN TO NEUTRAL SETTING (FOOT CONTROL) WARNING WARNING POTENTIAL FOR SERIOUS INJURY Certain procedures require the vehicle engine to be operated and the vehicle to be raised off the ground. To prevent possible injury to the servicing technician and/or bystanders, insure the vehicle is properly secured. The return to neutral mechanism on the transmission is designed to set the directional control into a neutral position when the operator removes their foot from the foot control.
BRAKE MAINTENANCE BRAKE SETTING FRICTION PACK ADJUSTMENT 1. Remove the brake arm bias spring, and then the cotter pin securing the brake castle nut. The friction pack dampens or holds the operator control lever in its desired position. 2. Insert a 0.015" feeler gage between the brake disc and top brake puck, and then set the brake by finger tightening or loosening the castle nut. 3. Install a new cotter pin to secure the castle nut, and then install the brake arm bias spring.
SECTION 5. REPAIR HOW TO USE THIS SECTION Each subassembly illustrated in this section is illustrated by an exploded view showing the parts involved. The item reference numbers in each illustration are for assembly instructions only. See pages 31 and 33 for part names and descriptions. A complete exploded view and item list of the transaxle is provided at the end of this section. IMPORTANT: When internal repair is performed on the 310-0510 IHT, the filter assembly must be replaced.
TOOLS AND TORQUES Table 4. Required Tools Miscellaneous 310-0510 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 Sockets 1/2"- 3/8" Adapter 1/2" Deep 7/16" Deep 9/16" Deep 3/4" Deep 7/8" 10 mm T-25 Torx Head Table 5.
BRAKE ASSEMBLY AND BYPASS ARM Refer to Figure 8. INSPECTION DISASSEMBLY 1. Inspect the brake arm bias spring (66), castle nut (69), washer (73), brake arm (68), actuating pins (62), spring (71), brake yoke screws (63/64), brake yoke (58), pucks (60), puck plate (61), bypass arm (49), spacer (65) and brake rotor (59) for wear or damage. 1. Remove the brake arm bias spring (66). Note the orientation of the spring for proper reassembly. 2.
CONTROL ARM AND FRICTION PACK Refer to Figure 9. 3. Inspect the inner wedge puck (90). DISASSEMBLY 4. Inspect the friction pack stud (76) for wear or damage. 1. Remove the brake assembly. See page 16. 2. Loosen and remove the friction pack lock nut (80), flat washer (73), spring (78), spacer (79), washer clip (82) and puck (77). Discard the lock nut (80). ASSEMBLY 1. Install the friction pack stud (76), if removed. Torque according to specifications in Table 5. 4.
SEAL KIT REPLACEMENT input shaft. 2. The seal (13) can be replaced by following steps 2-6 of the procedure used to replace the axle seals. Before disassembly, wipe the unit free of any debris to avoid contamination. Refer to Figure 10. Axle Seal Trunnion Seal 1. Remove the axle clips (93) from the axle horns (for units with keyed axle shafts). 2. Remove the seal retaining rings (12). 3. Carefully pull the axle seals (34) out of the housing bore with a “hook” type tool.
SIDE HOUSING Refer to Figure 11. ASSEMBLY DISASSEMBLY 1. Apply a bead of sealant around the perimeter of the side housing face. See sealant pattern on page 28. 1. Remove the brake assembly and bypass arm. See page 16. 2. Remove the control arm and friction pack. See page 17. 3. Remove the oil from the transaxle. See page 10. 4. After all of the oil has been removed from the transaxle, remove the housing screws (7) and torque strap screw (8). 5.
AXLE SHAFT, DIFFERENTIAL & REDUCTION GEARS Refer to Figure 12. block bearing and miter gears for wear or damage. DISASSEMBLY 3. Inspect the bull gear for wear or damage. 1. Remove the brake assembly and bypass arm. See page 16. 4. Inspect the reduction gears, shaft and washers. 2. Remove the control arm and friction pack. See page 17. 5. Inspect the housing bores. 3. Remove the oil from the transaxle. See page 10. 4. Remove the side housing. See page 19. 5.
MOTOR SHAFT AND BYPASS ROD 2. Inspect the bypass rod (48) for wear or damage. Refer to Figure 13. DISASSEMBLY 1. Remove the brake assembly and bypass arm. See page 16. 2. Remove the control arm and friction pack. See page 17. 3. Drain the oil from the transaxle. See page 10. 4. Remove the side housing. See page 19. 5. Remove the axle shaft, differential and reduction gears. See page 20. ASSEMBLY 1.
INPUT SHAFT Refer to Figure 14. ASSEMBLY DISASSEMBLY 1. Install the block thrust washer (56) and spring (55) onto the input shaft (9). 2. Ensure that the pump block is aligned concentrically with the center section running face. 3. Insert the input shaft (9), with bearing (14) and retaining ring (10), into the pump block assembly. NOTE: Do not force the shaft and bearing as damage may occur. If alignment is correct the shaft assembly will fit into place. 4.
HYDRAULIC COMPONENTS Refer to Figures 15-24. DISASSEMBLY 12. Reassemble the pistons, springs and seats into the cylinder block and set aside. (Pump Block) 13. (See Fig. 18) Remove the thrust bearing assembly (19) from the swashplate (4). 1. Remove the brake assembly and bypass arm. See page 16. (Center Section/Filter) 2. Remove the control arm and friction pack. See page 17. 3. Drain the oil from the transaxle. See page 10. 4. Remove the side housing. See page 19. 5.
HYDRAULIC COMPONENTS the pistons, piston springs and piston seats for excessive wear or damage. NOTE: Piston seats may be held in place in the piston by residual oil. 22. Reassemble the pistons, springs and seats into the cylinder block and set aside. 23. Remove the thrust bearing assembly (19) 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.
HYDRAULIC COMPONENTS 13. Tighten the center section mounting screws (44) to the proper torque. Refer to Table 5. (Swashplate/Pump Block) 14. (See Fig. 18) Install the pump thrust bearing (19) in the trunnion machined swashplate (4). NOTE: Place the thin race of the bearing towards the swashplate. The thick race must face the pistons. 4 15. (See Fig. 16) Place the pump block assembly (5), pistons down, on top of the thrust bearing in the swashplate (4). 5 16.
HYDRAULIC COMPONENTS Axle Horn 44 1 19 44 5 Figure 19 Figure 22 124 5 3 Figure 20 24 Figure 23 Short Shaft 3 46 Post Figure 24.
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.
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.
310-0710 INTEGRATED HYDROSTATIC TRANSAXLE DESCRIPTION TRANSAXLE REMOVAL The 310-0710 transaxle is an upgraded 310-0510 unit with different axle shafts, pump cylinder block assembly, center section and seal kit. The 310-0710 will have, as standard, black axle shafts. Black “E” coated housings and flanged hubs will be available options. It is necessary to remove the 310-0710 from the vehicle before performing the repair procedures presented in the repair section.
310-0710 EXPLODED VIEW 30 310-0510 IHT
310-0710 ITEMS LIST No. DESCRIPTION No. DESCRIPTION 1 Main Housing, Assembly, Black Main Housing, Black Bushing .865 X .985 X .790 Side Housing, Assembly, Black Side Housing, Black Bushing .865 X .985 X .790 Bushing .624 X .719 X .562 Center Section Assembly Center Section Machined Bushing .707 X .788 X .591 Swashplate, Trunion Machined Block - Assembly Block - Cylinder Piston Spring Compression Thrust - Washer Sealant Hex Flange Screw 1/4-20 X 1.
57—20W-50 OIL 127—SEAL & O-RING KIT 310-0510 EXPLODED VIEW 32 310-0510 IHT
310-0510 ITEMS LIST No. DESCRIPTION No. DESCRIPTION 1 Main Housing, Assembly Main Housing, Machined Bushing .865 X .985 X .790 Side Housing, Assembly Side Housing, Machined Bushing .865 X .985 X .790 Bushing .624 X .719 X .562 Center Section Assembly Center Section Machined Bushing .707 X .788 X .591 Swashplate, Trunion Machined Block - Assembly Block - Cylinder Piston Spring Compression Thrust - Washer Sealant Hex Flange Screw 1/4-20 X 1.
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.
GLOSSARY OF TERMS Hydrostatic Transaxle: A multi-component assembly including a gear case and a hydrostatic transmission. Hydrostatic Transmission: The combination of a hydraulic pump and motor in one housing to form a device for the control and transference of power. Inlet Line: A supply line to the pump. Integrated Hydrostatic Transaxle (IHT): The combination of a hydrostatic transmission and gear case in one housing to form a complete transaxle.
© 2001 HYDRO-GEAR Printed in U.S.A.
