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.
SECTION 1. DESCRIPTION AND OPERATION INTRODUCTION The purpose of this manual is to provide information useful in servicing the Hydro-Gear Integrated Zero Turn (IZT) transaxle. This manual includes the IZT’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.
310-2400 or or or 310-2600 or or or Figure 1.
310-2400 CHECK VALVE CYLINDER BLOCK ASSEMBLY CYLINDER BLOCK ASSEMBLY BYPASS ACTUATOR FIXED SWASHPLATE MOTOR SHAFT INPUT SHAFT VARIABLE SWASHPLATE VARIABLE DISPLACEMENT 10cc PUMP FIXED DISPLACEMENT 21cc MOTOR CHECK VALVE RESERVOIR TRANSAXLE HOUSING FILTER 310-2600 CHECK VALVE CYLINDER BLOCK ASSEMBLY BYPASS ACTUATOR CHARGE PUMP INPUT SHAFT CYLINDER BLOCK ASSEMBLY FIXED SWASHPLATE MOTOR SHAFT VARIABLE SWASHPLATE VARIABLE DISPLACEMENT 10cc PUMP FIXED DISPLACEMENT 21cc MOTOR CHECK VALVE RESERVOI
HYDRAULIC SCHEMATIC Figure 2 provides an illustration of the hydraulic oil circuits. The oil supply for the hydraulic system of the 310-2400 IZT and charged 3102600 IZT 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. Output of the oil flow is controlled by the direction and amount that the variable swashplate is angled.
EXTERNAL FEATURES 310-2400L Back Cover Back Cover Axle Shaft Disc Brake Assembly Hub Assembly Fill Port Cog Brake Assembly 6 Seal Plug Input Shaft Lower Cover Bypass Actuator Control Arm Assembly 310-2400/2600 IZT
EXTERNAL FEATURES 310-2600R Filter Charge Cover Charge Cover Back Cover Back Cover Axle Shaft Bypass Hub Assembly Charge Cover Filter Bypass Input Shaft Fill Port Oil Drain Filter Control Arm Assembly Charge Cover 310-2400/2600 IZT Lower Cover Seal Plug Cog Brake Assembly “Only” Charge Cover 7
TECHNICAL SPECIFICATIONS 210-2400 Axle Shaft Options Type: Keyed / Double “D” Diameter: 0.984 inch; 25.0 mm Type: Flanged Diameter: Hub Overall Transaxle Reduction 19.2:1 Input Speeds Maximum: 3000 RPM Minimum: 1800 RPM Tire Diameter 18 in maximum; 45.7cm with 325 lbs; 147.4 kg maximum weight on tires Brake Type Disc, Parking Cog, Parking Weight of Unit 30 lb; 13.6 kg 210-2600 Axle Shaft Options Type: Keyed / Double “D” Diameter: 0.984 inch; 25.
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 3102400/2600 IZT 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.
FLUIDS The fluids used in Hydro-Gear products have been carefully selected, and only equivalent, or better products should be substituted. Typically, an engine oil with a minimum rating of 55 SUS (9 cSt) at 230°F (110° C) and an API classification of SL is recommended. A SAE 20W-50 engine oil has been selected for use by the factory and is recommended for normal operating temperatures. FLUID VOLUME AND LEVEL Fluid volume information is provided in Table 3.
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 normally approved for use in hydrostatic drive systems.
RETURN TO NEUTRAL SETTING 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 hands from the control.
BRAKE MAINTENANCE COG BRAKE MAINTENANCE FRICTION PACK ADJUSTMENT 1. Check the brake arm teeth for damage or excessive wear. Replace if necessary. The friction pack dampens or holds the operator control lever in its desired position. 2. Check for excessive looseness at brake arm pivot point. Adjustment for the amount of drag or holding force can be made by turning the friction pack nut in or out. DISC BRAKE MAINTENANCE (310-2400 Only) 1.
SECTION 5. REPAIR HOW TO USE THIS SECTION TRANSAXLE REMOVAL 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 34,35,36 and 37 for part names and descriptions. A complete exploded view and item list of the transaxle is provided at the end of this section.
TOOLS AND TORQUES Table 4. Required Tools Miscellaneous 310-2400 Service & Repair Manual Flat Blade Screw Driver Torque Wrench Air Impact Wrench Rubber Mallet Pliers Needle Nose Large External Snap Ring Small External Snap Ring Large Internal Snap Ring Sockets 3/8" 1/2" 7/16" 9/16" E-8 Torx Head Wrenches 1/2" 5 mm Allen 3/8” Allen 1/4” Allen Table 5.
BACK COVER Refer to Figure 8. ASSEMBLY DISASSEMBLY 1. Apply sealant to the back cover (1). Refer to page 29. 1. Remove the eight screws (50) from the back cover (13), and discard. 2. Remove the back cover (13). Take care not to damage the casting surfaces. 3. Clean off the sealant from the mating surfaces of the back cover (13) and the main housing assembly (1). 2. Place the back cover (13) onto the main housing assembly (1). 3.
BRAKES (Cog Brake) ASSEMBLY Refer to Figure 9. 1. Insert the brake shaft (55) into the main housing (1). Slide the brake disc (73) onto the brake shaft (55). Note the orientation of the brake disc. The hub on the brake disc should face inward on R.H. units and outward on L.H. units. DISASSEMBLY 1. Remove the external retaining ring (63). 2. Remove the brake bolt (123), brake arm (70) and brake disc (73). Note the orientation of the hub on the brake disc. INSPECTION 1.
BRAKES (Disc Brake 210-2400 Only) ASSEMBLY Refer to Figure 10. 1. Slide the stators (127) and rotor (73) onto the brake shaft (55, Figure 11). Pay close attention to the stack up of the stators and rotor. DISASSEMBLY 1. Remove the cotter pin (128) and slotted hex nut (133). Discard the cotter pin. 2. Remove the washer (19), brake arm (70), compression spring (130) and brake actuating pins (129). 3. Remove the three brake yoke screws (123). Remove the brake yoke (131). 4.
BRAKE SHAFT & BEVEL GEAR Refer to Figure 11. INSPECTION DISASSEMBLY 1. Inspect the brake shaft (55), ball bearing (26) and bevel gear (52) for wear or damage. 1. Remove the back cover. See page 18. 2. Remove the brake. See pages 19-20. ASSEMBLY 3. Remove the brake shaft lip seals (58) and retaining rings (126). Discard the lip seals (58). 4. Remove the retaining ring (67) from the outside of the ball bearing (26). 5. Remove the brake shaft (55) and ball bearing (26) from the 19 tooth bevel gear (52).
AXLE SHAFT & SPUR GEAR Refer to Figure 12. ASSEMBLY DISASSEMBLY 1. Place the spur gear (53) and axle bushings (81&82), per noted orientation, into the main housing (1). 1. Remove the back cover. See page 18. 2. Remove the brake. See page 19-20. 3. Remove the brake shaft and bevel gears. See page 21. 4. Remove the hub assembly (107), if not already removed. Note: The orientation of the hub and axle to the main housing is critical in reassembly. 2.
AXLE SHAFT & SPUR GEAR 68 62 60 64 81 53 1 82 65 68 56 66 107 108 Figure 12.
LOWER HOUSING & FILTER Refer to Figure 13. ASSEMBLY DISASSEMBLY 310-2400 1. Install a new filter (46). 1. Remove the ten screws (50) holding the lower housing (2) to the main housing (1), and discard. 2. Apply sealant to the lower housing (2) where the lower housing (2) mates with the main housing (1). Refer to page 29. 2. Remove the lower housing (2) and old sealant. Take care not to damage the casting surfaces. 3. Place the lower housing (2) on the main housing (1). 3.
LOWER HOUSING & FILTER wear or damage. Refer to Figure 14. DISASSEMBLY 310-2600 1. Place an orientation mark on the charge cover. 2. Remove the two screws (86), charge cover (85), o-ring (83) and gerotor assembly (84). 3. Remove filter assembly (46). 4. Remove the ten screws (50) holding the lower housing (2) to the main housing (1), and discard. 5. Remove the lower housing (2) and old sealant. Take care not to damage the casting surfaces. INSPECTION 1. Inspect the lower housing (2) for excessive 2.
MOTOR SHAFT & BEVEL GEAR Refer to Figure 15. ASSEMBLY DISASSEMBLY 2. Remove the brake. See pages 19 & 20. 1. Install the motor shaft (54), bearing assembly (26) and wire retaining ring (27). Note: The splines must be aligned when inserting the motor shaft (54). 3. Remove the brake shaft & bevel gear. See page 21. 2. Install the 14 tooth bevel gear (51) on the end of the motor shaft (54). 4. Remove the axle shaft & spur gear. See pages 22 & 23. 3. Install the axle shaft and spur gear.
CENTER SECTION, CYLINDER BLOCKS AND BYPASS Refer to Figure 16. INSPECTION DISASSEMBLY 1. Check the pistons in the motor and pump blocks for free movement. 1. Remove the back cover. See page 18. 2. Remove the brake assembly. See pages 19 and 20. 3. Remove the brake shaft and bevel gear. See page 21. 2. Remove and inspect the pistons, springs and seats for wear or damage. 3. Inspect the piston bores in the cylinder blocks for wear or damage. 5. Remove the lower housing and filter. See page 24 and 25.
CENTER SECTION, CYLINDER BLOCKS AND BYPASS 8. Install the two pins (43). 9. Install the by-pass plate (38) into the center section (3). Install the center section (3) and motor cylinder block assembly (21). 13. Install the filter and lower housing. See page 24 and 25. 14. Install the axle shaft and spur gear. See pages 22 and 23. 10. Install the three screws (44) that hold the center section (3) in place. 15. Install the brake shaft and bevel gear. See page 21. 11.
INPUT SHAFT & TRUNNION ARM Refer to Figure 17. ASSEMBLY DISASSEMBLY 1. Install the trunnion arm (31) if removed and install a new trunnion seal (33). 1. Remove the back cover. See page 18. 2. Remove the brakes. See pages 19 and 20. 2. Install the slot guide (30). 3. Remove the brake shaft and bevel gear. See page 21. 3. Install the input shaft (12), bearing assembly (8) and wire retaining ring (6), if removed. 4. Remove the axle shaft and spur gear. See pages 22 and 23. 4. Install the spacer (5).
INPUT SHAFT & TRUNNION ARM 7 4 5 6 8 33 30 31 1 9 12 Note: Cradle bearings are nonremovable. Shown removed for illustration purposes only. 12 Charged Standard Figure 17.
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. Install the hub assembly (107, page 23) if not already done. Install the ¾-16 hex nut (108, page 23). 3. With the vehicle raised, install the wheel on the hub, and snug the wheel lug nuts. 4. Lower the vehicle wheels to the ground and torque the ¾-16 hex nut to 200-295 ft.-lbs.
SEALANT APPLICATION NOTE: Prior to applying the new sealant, the old sealant must be removed from all surfaces. A small bead of the sealant around the outer part of the housing face will be sufficient. Use sparingly. The illustrations below indicate the correct areas.
Service Bulletin PRODUCTS AFFECTED: All Hydro-Gear IZT models (310-2400 Series) SB-51888 Rev. P SUBJECT: Water Exclusion Kit DESCRIPTION: It has been determined that on some IZT applications, water intrusion, resulting from unprotected exposure to the environment or high pressure washing is possible. This bulletin details the parts to be used in preventing the potential for water intrusion. This is a preventative product improvement: Not intended for Hydro-Gear warranty reimbursement.
34 126 58 52 THICK RACE TOWARD PISTONS 25 55 100 11 1 27 50 (10X) 21 26 100 54 51 38 10 43 39 43 2 44 (3X) 121 33 31 46 3 15 24 14 12 136 127 73 76 36 120 126 7 58 4 26 67 30 8 13 THICK RACE TOWARD PISTONS 50 (8X) 5 6 40 99 41 42 137 135 49 37 35 129 131 127 35 68 71 60 82 19 64 215 62 129 123 133 19 122 119 19 63 70 209 208 215 53 123 105 56 207 81 80—20W-50 OIL 134—SEAL KIT INCLUDES ITEMS 4, 7, 33, 40, 42, 50, 58, 60, 62, 66, 67, 6
ITEMS LIST No. DESCRIPTION No.
310-2600 EXPLODED VIEW 108 107 68 49 135 136 137 210 66 123 110 120 42 41 111 142 40 13 4 26 5 7 73 67 63 65 126 58 56 81 81 6 8 82 8X 50 60 62 64 53 81 68 55 19 52 126 70 208 34 215 58 1 10 143 33 35 30 THICK RACE 11 TOWARD PISTONS 31 39 51 215 207 19 216 27 12 26 43 38 209 24 14 15 54 3 25 21 43 48 150 7 78 76 77 78 3X 44 2 10X 50 80 - 20w-50 OIL 100 - SEALANT 134 - SEAL KIT INCLUDES ITEMS 4, 7,33, 40, 42, 50, 58, 60, 62, 66, 67, 68 83, AND 126
310-2600 ITEMS LIST No.
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.
© 2004 HYDRO-GEAR Printed in U.S.A.
