Hydro-Gear 310-2200%20EZT, 310-2200-EZT Parts Lists and Service Repair Manuals

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310-2200 EZT
Integrated Zero-Turn Transaxle
Service and Repair Manual
BLN-51856
December 2008
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Section Page
Foreword............................................................................................................................. 1
Description and Operation ................................................................................................ 2
Introduction .................................................................................................................................................. 2
General Description ..................................................................................................................................... 2
Hydraulic Schematic.................................................................................................................................... 3
External Features 310-2200 ......................................................................................................................... 4
Technical Specifications ............................................................................................................................... 5
Product Identification ................................................................................................................................... 5
Safety .................................................................................................................................. 6
Personal Safety ........................................................................................................................................... 6
Tool Safety................................................................................................................................................... 6
Work Area Safety ........................................................................................................................................ 6
Servicing Safety ........................................................................................................................................... 6
Troubleshooting .................................................................................................................7
Service and Maintenance .................................................................................................. 8
External Maintenance .................................................................................................................................. 8
Service and Maintenance Procedures .......................................................................................................... 8
Fluids .......................................................................................................................................................... 8
Fluid Volume and Level ................................................................................................................................8
Fluid Change Procedure .............................................................................................................................. 9
Purging Procedures ................................................................................................................................... 10
Return to Neutral Setting ........................................................................................................................... 11
Repair ................................................................................................................................ 13
How To Use This Section ........................................................................................................................... 13
General Instructions ................................................................................................................................... 13
Transaxle Removal ..................................................................................................................................... 13
Limited Disassembly ................................................................................................................................. 13
Tools and Torques ...................................................................................................................................... 14
Control Arm and Bypass Arm ..................................................................................................................... 15
Seal Kit Replacement ................................................................................................................................ 16
Cog Brake and Side Housing ..................................................................................................................... 17
Axle Shaft, Reduction Gears and Expansion Plate .................................................................................... 18
Motor Shaft ................................................................................................................................................ 19
Input Shaft and Bypass Rod ...................................................................................................................... 20
Hydraulic Components .......................................................................................................................... 21-25
Transaxle Installation ................................................................................................................................. 25
Assembly After a Complete Teardown ........................................................................................................ 26
Sealant Application........................................................................................................... 27
Parts List ..................................................................................................................... 28, 29
Glossary of Terms ...................................................................................................... 30, 31
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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.
This Service and Repair Manual is designed to provide information useful in servicing and troubleshooting the Hydro-Gear 310-2200 EZT Integrated Zero-Turn Transaxle.
Also included is a glossary of terms that are frequently used throughout the industry and in Hydro-Gear service publications. Understand­ing terminology is very important!
It is necessary, and a good shop practice, that your service area be equipped with the proper tools and the mechanics be supplied the latest information available. All repair procedures il­lustrated in this guide are suggested, but pre­ferred methods of repair.
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Repair procedures require that the transaxle unit be removed from the vehicle.
This is not a certification, test or study guide for a certification test. If a technician is interested in certification, they should contact an agent representing the ESA (Engine Service Associa­tion) at (610) 363-3844 or their Hydro-Gear Central Service Distributor. Many distributors will be hosting certification testing. These study
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guides will cover most of the products and manu­facturers in our industry.
For more information about Hydro-Gear or our products, please contact your Central Service Distributor, or call our Customer Service De­partment at (217) 728-2581.
310-2200 EZT
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SECTION 1. DESCRIPTION AND OPERATION
INTRODUCTION
The purpose of this manual is to provide infor­mation useful in servicing the Hydro-Gear® Inte-
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grated Zero-Turn Transaxle (EZT 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. Should other servicing be required, the exterior of the transaxle will need to be thor­oughly cleaned before beginning most proce­dures. Do not wash the transaxle while it is hot. Do not use a pressure washer to clean the unit.
). This manual
GENERAL DESCRIPTION
The 310-2200 is a self contained unit designed for the transfer and control of power. It provides an infinitely variable speed range between zero and maximum in both forward and reverse modes of operation.
pump and thus reverses the direction of the mo­tor output rotation. The pump and motor are of the axial piston design and utilize spherical nosed pistons which are held against a thrust race by internal compression springs.
The 310-2200 has a self contained fluid supply and an internal filter. The fluid is forced through the filter by a positive “head” on the fluid in the housing/expansion tank with an assist by the negative pressure created in the pump pistons as they operate.
The check valves in the center section are used to control the make-up flow of the fluid to the low pressure side of the loop.
A cam style, block lifting bypass is utilized in the 310-2200 to permit moving the vehicle for a short distance at a maximum of 2 m.p.h. (3.2 Km/h) without starting the engine.
WARNING
This transaxle uses a variable displacement pump with a maximum displacement of 10cc per revolution, and motor with a fixed displacement of 10cc per revolution. The variable displace­ment pump features a trunnion mounted swashplate with a direct-proportional displace­ment control. Reversing the direction of the swashplate reverses the flow of oil from the
Actuating the bypass will result in the loss of hydrostatic braking capacity. The machine must be stationary on a level surface and in neutral when actuating the bypass.
Figure 1. Hydraulic Schematic
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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. Output of the oil flow is controlled by the direction and amount that the variable swashplate is angled. As the pump pis­tons compress they force the oil to flow through one of two passageways (forward or reverse) in the center section to the motor cylinder block and motor shaft. Since the motor has a fixed displacement angle it is forced to turn with the flow of oil. As the angle of the pump swashplate is increased the amount of oil being pumped will
increase and cause a higher speed output of the motor. Reversing the angle of the pump swashplate will reverse the direction of oil flow.
During the operation of the transaxle, fluid is “lost” from the hydraulic loop through leak paths designed into the product for lubrication purposes (around pistons, under the rotating cylinder blocks, etc.). This “lost” fluid returns to the transaxle housing, then is pulled back into one of the check valves depending upon the direc­tion of vehicle operation. All of this oil must pass through an internal filter.
The motor cylinder block mounts onto a splined motor shaft which drives the gear train.
The bypass feature in the 310-2200 has a me­chanical lever which lifts the motor block off of the center section running surface. This allows oil flow from the cylinder blocks to be discharged.
310-2200 EZT
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EXTERNAL FEATURES 310-2200
4 310-2200 EZT
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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 20 inch; 508 mm Minimum: 1800 RPM
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. 310-2200 EZT® Component Options
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:snoitpOdnEdnaretemaiDtfahSelxA
:noitacoLekarB
:epyTekarB
:noitacoLmrAlortnoC
:stnemegnarrAlortnoC
:noitcudeRelxasnarTllarevO
DD"4/3egnalF"1shtgnelsuoiravDD"1 draobnIdraobtuO
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adnatS)elytsrossics(NTR
1:2.911:2.12
mrAlortnoCdr
PRODUCT IDENTIFICATION
The model and configuration of the 310-2200 EZT® can be determined from the label shown in Figure 3.
310-2200 EZT
Figure 3. Configuration Label
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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.
WARNING
POTENTIAL FOR SERIOUS INJURY
Inattention to proper safety, operation, or maintenance procedures could result in personal injury, or damage to the equip­ment. Before servicing or repairing the 310-2200 EZT®, fully read and under­stand the safety precautions described in this section.
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 slip-proof shoes.
Never use compressed air to clean debris from yourself or your clothing.
TOOL SAFETY
Use the proper tools and equipment for the task. Inspect each tool before use and replace any
tool that may be damaged or defective.
WORK AREA SAFETY
Keep the work area neat and orderly. Be sure it is well lit, that extra tools are put away, trash and refuse are in the proper containers, and dirt or debris have been removed from the working areas of the machine.
PERSONAL SAFETY
Certain safety precautions must be observed while servicing or repairing the 310-2200 EZT®. This section addresses some of these precau­tions but must not be considered an all-inclusive source on safety information. This section is to be used in conjunction with all other safety mate­rial which may apply, such as:
1) Other manuals pertaining to this machine,
2) Local and shop safety rules and codes,
3) Governmental safety laws and regulations.
Be sure that you know and understand the equip­ment and the hazards associated with it. Do not place speed above safety.
Notify your supervisor whenever you feel there is any hazard involving the equipment or the per­formance of your job.
Never allow untrained or unauthorized person­nel to service or repair the equipment.
The floor should be clean and dry, and all exten­sion cords or similar trip hazards should be re­moved.
SERVICING SAFETY
Certain procedures may require the vehicle to be disabled in order to prevent possible injury to the servicing technician and/or bystanders.
The loss of hydrostatic drive line power may result in the loss of hydrostatic braking capabil­ity.
Some cleaning solvents are flammable. Use only approved cleaning materials: Do not use explo­sive or flammable liquids to clean the equipment.
To avoid possible fire, do not use cleaning sol­vents in an area where a source of ignition may be present.
Discard used cleaning material in the appropri­ate containers.
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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!
not related to a defective transaxle, but are caused by slipping drive belts, partially engaged bypass valves, and loose or damaged control linkages. Be sure to perform all operational checks and adjustments outlined in Section 4, Service and Maintenance, before assuming the pump is malfunctioning. Table 3 below provides
In many cases, problems with the 310-2200 are
Follow all safety procedures outlined in the vehicle owner’s manual.
Table 3. 310-2200 EZT® Troubleshooting Checklist
a troubleshooting checklist to help determine the cause of operational problems.
Possible Cause Corrective Action
UNIT OPERATES IN ONE DIRECTION ONLY
Control linkage bent or out of adjustment Repair or replace linkage, Page 8 Drive belt slipping or pulley damaged Repair or replace drive belt or pulley, Page 8
VEHICLE DOES NOT DRIVE/TRACK STRAIGHT
Vehicle tires improperly inflated Refer to vehicle manufacturer suggested pressure Control linkage bent or out of adjustment Repair or replace linkage, Pages 8 and 11 Bypass assembly sticking Repair or replace bypass, Page 20
UNIT IS NOISY
Oil level low or contaminated oil Fill to proper level or change oil, Page 9 Excessive loading Reduce vehicle loading, Page 8 Loose parts Repair or replace loose parts
Bypass assembly sticking Repair or replace linkage Air trapped in hydraulic system Purge hydraulic system, Page 10
UNIT HAS NO/LOW POWER
Engine speed low Adjust to correct setting Control linkage bent or out of adjustment Repair or replace linkage, Page 8 Drive belt slipping or pulley damaged Repair or replace drive belt or pulley, Page 8
Oil level low or contaminated oil Fill to proper level or change oil, Page 9 Excessive loading Reduce vehicle loading, Page 8 Bypass assembly sticking Repair or replace linkage Air trapped in hydraulic system Purge hydraulic system, Page 10
UNIT IS OPERATING HOT
Debris buildup around transaxle Clean off debris, Page 8 Cooling fan damaged Repair or replace cooling fan Oil level low or contaminated oil Fill to proper level or change oil, Page 9 Excessive loading Reduce vehicle loading, Page 8 Air trapped in hydraulic system Purge hydraulic system, Page 10
TRANSAXLE LEAKS OIL
Damaged seals, housing, or gaskets Replace damaged component Air trapped in hydraulic system Purge hydraulic system, Page 10
310-2200 EZT
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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
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EZT
should include the following:
1. Check the vehicle operator’s manual for the recommended load ratings. Insure that the current application does not ex­ceed load rating.
2. Check oil level in accordance with Figure 4 Page 9.
3. Inspect the vehicle drive belt, idler pulley(s), and idler spring(s). Insure that no belt slip­page can occur. Slippage can cause low in­put speed to the transmission.
4. Inspect the vehicle control linkage to the di­rectional control arm on the transaxle. Also insure that the control arm is securely fas­tened to the trunnion arm of the transaxle.
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
9.0 cSt (55 SUS) at 230° F (110° C) and an API classification of SL is recommended. A 20W50 engine oil has been selected for use by the fac­tory and is recommended for normal operating procedures.
FLUID VOLUME AND LEVEL
Fluid volume information is provided in Table 4.
Certain situations may require additional fluid to be added or even replaced. Refer to Page 4 and Figure 4 for the proper fill port location.
Fill the 310-2200 so the oil level is .75”-1.50” (19-38 mm) below the oil fill port.
Recheck the fluid level once the unit has been operated for approximately 1 minute.
Purging will be required. Refer to the purging procedures on Page 10.
5. Inspect the bypass mechanism on the transaxle and the vehicle linkage to insure that both actuate and release fully.
SERVICE AND MAINTENANCE PROCEDURES
Some of the service procedures presented on the following pages can be performed while the 310-2200 is mounted on the vehicle. Any repair procedures as mentioned in the repair section of this manual must be performed after the unit has been removed from the vehicle.
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FLUID CHANGE PROCEDURE
FLUID CHANGE
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.
3. Remove the oil fill port fitting.
4. Position the transaxle so the oil will drain completely out of the housing.
Table 4. Fluid Volumes for the 310-2200 EZT
Fluid Description
20W50 engine oil
5. Fill the transaxle at the oil fill port according to Figure 4.
6. Install the oil fill port fitting.
7. Purging will be required. Refer to the purg­ing procedures on Page 10.
8. Recheck the fluid level once the unit has been operated for approximately 1 minute.
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Volume
54.1 fl.oz. (1600 ml) to 57.5 fl.oz. (1700 ml)
310-2200 EZT
Figure 4. Fluid Level and Fill Port
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PURGING PROCEDURES
Due to the effects air has on efficiency in hydro­static drive applications, it is critical that it is 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.
The resulting symptoms in hydrostatic systems may be:
1. Noisy operation.
2. Lack of power or drive after short term op­eration.
3. High operation temperature and excessive expansion of oil.
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.
The following procedures should be performed with the vehicle drive wheels off the ground, then repeated under normal operating conditions.
1. With the bypass valve open and the engine running, slowly move the directional control in both forward and reverse directions (5 or 6 times), as air is purged from the unit, the oil level will drop.
2. With the bypass valve closed and the engine running, slowly move the directional control in both forward and reverse directions (5 to 6 times). Check the oil level, and add oil as required after stopping the engine.
3. It may be necessary to repeat Steps 1 and 2 until all the air is completely purged from the system. When the transaxle moves for­ward and reverse at normal speed purging is complete.
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RETURN TO NEUTRAL SETTING
WARNING
POTENTIAL FOR SERIOUS INJURY
Inattention to proper safety, operation, or maintenance procedures could result in personal injury, or damage to the equip­ment. Before servicing or repairing the 310-2200 EZT®, fully read and under­stand the safety precautions described in this section.
The return to neutral mechanism on the transmis­sion is designed to set the directional control into a neutral position when the operator releases the vehicle hand control. Follow the procedures be­low to properly adjust the return to neutral mecha­nism on the transaxle:
1. Confirm the transaxle is in the operating mode (bypass disengaged). Raise the vehicle’s drive tires off the ground to allow free rotation.
NOTE: It may be necessary to remove the drive tire from the axle hub to access the link­age control and the transaxle return arm.
2. Remove the Original Equipment Manufacturer’s (OEM’s) control linkage at the control arm. Refer to Figure 5.
3. Start the engine and increase the throttle to full engine speed.
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.
4. Check for axle rotation. If the axle does not
rotate, go to Step 5. If the axle rotates, go to Step 6.
5. Stop the vehicle’s engine. Reattach and ad-
just the OEM linkage according to Step 3 and Step 4. Stop the vehicle engine. Refer to Figure
5.
6. Note the axle directional movement. Stop the
vehicle engine. Loosen the RTN adjustment screw until the control arm can be rotated. Ro­tate the control arm in the opposite direction of the wheel rotation in 5 degree increments. Tighten the RTN adjustment screw. Refer to table 6. Required Torque values, page 14. Re­check according to steps 3 and 4. Stop the ve­hicle engine. Reattach and adjust the OEM link­age according to the OEM manual. Recheck ac­cording to steps 3 and 4. Refer to Figure 5.
310-2200 EZT
RTN Adjustment Screw
Speed and Directional Control
Figure 5. Return to Neutral Setting (Model 618-04163)
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NOTES
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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 de-
scriptions. A complete exploded view and item list of the transaxle is provided at the end of the repair section.
GENERAL INSTRUCTIONS
Cleanliness is a primary means of assuring satisfactory life on repaired units. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning of all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals.
Protect all exposed sealing surfaces and open cavities from damage and foreign material. The external surfaces should be cleaned before beginning any repairs.
Parts requiring replacement must be replaced from the appropriate kits identified in the Items Listing, found at the end of this manual. Use
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only original Hydro-Gear found in BLN-51427 (CD).
IMPORTANT: When internal repair is performed on the 310-2200 EZT®, the filter assembly must be replaced.
replacement parts
TRANSAXLE REMOVAL
It is necessary to remove the 310-2200 from the vehicle before performing the repair proce­dures presented in this section.
LIMITED DISASSEMBLY
The following procedures are presented in the order in which they must be performed to com­pletely disassemble the unit. Do not disassemble the unit any farther than is necessary to accom­plish the required repairs. Each disassembly pro­cedure is followed by a corresponding assem­bly procedure.
Upon removal, it is recommended that all seals, O-rings, and gaskets be replaced. During in­stallation lightly lubricate all seals, O-rings and gaskets with a clean petroleum jelly prior to assembly. Also protect the inner diameter of seals by covering the shaft with a cellophane (plastic wrap, etc.) material.
Reassembly is accomplished by performing the “Assembly” portions of the procedures. If the unit has been completely disassembled, a sum­mary of the assembly procedures, in the order in which they should occur, is given on page 24.
310-2200 EZT
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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
Table 6. Required Torque Values
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
Operation Torque Item Description
Side Housing Screws 135-185 lb-in [15-21 Nm] 9 Screw 1/4-20 x 1.25 Control Arm Screw 230-310 lb-in [26-35 Nm] 25 Screw 5/16-24 x 1 Control Arm Stop Stud 50-120 lb-in [6-18 Nm] 21 Stud 5/16-24 Center Section Bolts 525-700 lb-in [60-80 Nm] 12 Screw 3/8-24 x 2.5 Check Plugs 200-360 lb-in [23-41 Nm] 56 Check Plug Assembly Expansion Plate Screws 25-50 lb-in [3-6 Nm] 53 Screw 10-32 x 0.50 Fan/Pulley Lock Nut 360-520 lb-in [41-59 Nm] 122 Lock Nut 1/2 x 20 Cog Brake Bolt 80-120 lb-in [9-14 Nm] 55 Bolt 1/4-20 x 1 RTN Adjustment Screw 85-120 lb-in [10-14 Nm] 131 Screw 5/16-24 x 1.00 Hub Nut 100-160 lb-ft [136-217 Nm] 99 Nut, Hex 3/4-16 Lock
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CONTROL ARM AND BYPASS ARM
Refer to Figure 6.
Disassembly
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. Remove the bypass arm retaining ring (18) and bypass arm (17). Discard the retaining ring.
5. If necessary, remove and replace the con­trol arm stop stud (21).
Inspection
Assembly
1. Install the bypass arm (17) onto the bypass rod. Secure the bypass arm with a new re­taining ring (18).
2. Replace the control arm stop stud (21) if removed. Torque according to specifications in Table 6 on page 14.
3. Install the control arm (23).
4. Install the control arm screw (25). Refer to Table 6 for screw torque specifications.
1. Inspect the control arm stop stud (21) for wear or damage.
2. Inspect the control arm (23) for wear or dam­age.
3. Inspect the bypass arm (17) for wear or dam­age.
310-2200 EZT
Figure 6. Control Arm and Bypass Arm
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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. Lubricate the new seal with petroleum jelly prior to installation.
5. Wrap the shaft keyway (splines) with cello­phane to prevent damage to the seal lip dur­ing installation.
6. Slide the seal over the shaft and press it into the housing bore.
Trunnion Seal
1. Remove the control arm and any attachments to the control arm. See page 15.
2. The seal (20) can be replaced by following steps 3-6 of the procedure used to replace the input shaft.
Bypass Seal
1. Remove the bypass arm and any attach­ments to the bypass arm. See page 15.
2. Remove the seal retaining ring (16). Remove the bypass rod, keeping the retaining ring (14) attached. Remove the bypass rod seal (13). Deburr the bypass rod.
3. Install the seal (13). Install the bypass rod with the retaining ring (14) attached. Install the seal retaining ring (16).
7. The seal should seat against the spacer.
8. Install the seal retaining ring (34) and make sure it is fully seated in its groove.
Output Seal
1. The seal (51) can be replaced by following steps 2-6 of the procedure used to replace the input seal.
2. Install the retaining ring (34) and make sure it is fully seated in its groove.
Motor Shaft Seal
1. Remove the cog brake. See page 17.
2. The seal (10) can be replaced by following steps 3-6 of the procedure used to replace the input shaft.
Figure 7. Seal Kit Replacement
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COG BRAKE AND SIDE HOUSING
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. Pull the side housing (2), leaving the axle (49) and bull gear (46) assembled in the main housing. It may be necessary to use screw­drivers at the pry points to break loose the sealant (positions H-L and M-P, Figure 8).
7. Clean off main housings. Take care not to damage the sealing surfaces. A wire brush and solvent is effective.
all the old sealant on the side and
Inspection
1. Check the brake arm brake disc for exces­sive wear or teeth damage. Replace if nec­essary.
2. Check for excessive looseness at the arm pivot point.
3. Inspect the bearing and bushing areas in the side housing.
Assembly
1. Apply a bead of sealant around the perim­eter of the side housing face. See sealant pattern on page 27.
2. Install the locating pins (8), if not already in­stalled.
3. Install the side housing (2). Use care not to smear the sealant bead.
4. Install the side housing screws (9). Refer to the screw tightening pattern in Figure 8 and torque specification in Table 6 on page 14.
5. Install the remaining seals. Refer to page 16. Remember to use a seal protector during in­stallation.
6. Install the brake disc (100), retaining ring (14) and brake arm assembly (55).
7. Fill the transaxle with new oil. See page 9.
8. Install the bypass arm and control arm. See page 15.
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Figure 8. Cog Brake and Side Housing Assembly
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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.
Disassembly
1. Remove the bypass arm and control arm. See page 15.
2. Remove oil from the transaxle. See page 9.
3. Remove the side housing. See page 17.
4. Remove the spiral retaining ring (45), bull gear (46), inboard sleeve bearing (48) and washer (47).
5. Remove the reduction gears (42 &43), jack shaft pin (44) and washers (41).
6. Remove seal retaining ring (34), seal (51), axle (49) and bushing (50).
7. If necessary, remove the expansion plate as­sembly (53).
NOTE: Expansion plate removal will typically
destroy the plate. Clean all sealant from the expansion plate area.
Inspection
1. Inspect the bull gear for wear or damage.
2. Inspect the reduction gears, jack shaft pin and washers.
3. Inspect the axle shaft, bearing and bushing.
4. Inspect the expansion plate.
Assembly
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.
2. Reassemble and install the reduction gears (42 & 43), jack shaft pin (44) and washers (41).
3. Install the bull gear (46), retaining ring (45), bearing (48) and washer (47) onto the axle (49).
4. Install the axle (49) and bushing (50) into the housing (1).
5. Install the axle seal (51) and retaining ring (34).
6. Install the side housing. See page 17.
7. Install all remaining seals. See page 16.
8. Fill the transaxle with oil. See page 9.
9. Install the bypass arm and control arm. See page 15.
Figure 9. Axle Shaft, Reduction Gears and Expansion Plate
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
MOTOR SHAFT
Refer to Figure 10.
Disassembly
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).
Inspection
1. Inspect the motor shaft (39), pinnion gear (38) and flat washers (36 & 40) for wear or dam­age.
Assembly
1. Insert the motor shaft (39) with the pinnion gear (38) and flat washers (36 & 40) into the center section (57).
2. Install the reduction gears. See page 18.
3. Install the side housing. Refer to page 17.
4. Install new seals. Refer to page 16.
5. Fill the transaxle with oil. See page 9.
6. Install the bypass arm and control arm. See page 15.
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Figure 10. Motor Shaft
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INPUT SHAFT AND BYPASS ROD
Refer to Figure 11.
Disassembly
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 the motor shaft. See page 17.
6. Remove the retaining ring (34) and shaft seal (33). Discard the seal.
7. Remove the spacer (32) and input shaft as­sembly (29, 30 & 31).
8. Remove the compression spring (27) and washer (28).
5. Deburr the end of the bypass rod. Install the bypass rod (15), retaining ring (14), seal (13) and retaining ring (16).
6. Install the motor shaft. See page 19.
7. Install the reduction gears. See page 18.
8. Install the side housing. See page 17.
9. Install new seals in the side housing. See page 16.
10.Fill the transaxle with oil. See page 9.
11.Install the bypass arm and control arm. See page 15.
9. Remove the rings (14 & 16), bypass rod (15) and seal (13).
Inspection
1. Inspect the input shaft components and by­pass rod for wear or damage.
Assembly
1. Visually ensure that the pump block is aligned concentrically with the center section run­ning face.
2. Install the compression spring (27) and washer (28).
3. Insert the input shaft (29), with bearing (30) and retaining ring (31), 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. Install the washer (32), seal (33) and retain­ing ring (34). Use a seal protector when in­stalling the input shaft seal.
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Figure 11. Input Shaft and Bypass Rod Assembly
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
HYDRAULIC COMPONENTS
Refer to Figures 12-21.
Disassembly
1. Remove the bypass arm and control 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 the motor shaft. See page 19.
6. Remove the input shaft and bypass rod. See page 20.
7. (See Figure 12) Remove the swashplate (19) and pump cylinder block (4) as one as­sembly. NOTE: Removal will be aided by ap­plying a small amount of pressure on the trun­nion mounted swashplate towards the cen­ter section. Also note that the control arm (23, page 28) may be loosely assembled at this point to assist in swashplate removal. While gently removing the swashplate and block assembly, keep the block face flush with the center section to minimize damage to the running surface.
(Center Section/Filter)
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.
13.Remove the center section and filter assem­bly (57, Figure 17). NOTE: Bypass plate (Fig­ure 17) may slide out of the center section.
14.Remove the filter cover by pressing in and down on the filter cover tabs. Discard the cover.
15.Note the location of both check plugs (56) before removal for correct replacement dur­ing reassembly. Remove and inspect the check plug assemblies (56) for debris or damage.
16.Remove the filter base (61) and discard it. NOTE: The filter base is included in the filter kit to be installed during reassembly of the unit.
8. (See Figure 13) Disassemble the pump cyl-
inder block (4) from the swashplate (19).
9. (See Figure 14) Check each piston for
proper operation by pressing the pistons in and releasing them in the block bore. Disas­semble the pump cylinder block. Check for piston/block wear in the cylinder bore. Inspect the pistons (A), piston springs (C) and thrust washers (B) for excessive wear or damage. NOTE: Thrust washers may be held in place in the piston by residual oil.
10.Reassemble the pistons, springs and wash­ers into the cylinder block and set aside.
11. (See Figure 15) Remove the thrust bearing assembly (35) from the swashplate (19).
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(Motor Block)
17.(See Figure 19) Remove the motor cylinder
block assembly (4) from the housing (1).
18.Disassemble the motor cylinder block as­sembly (4). Check each piston for proper operation by pressing the pistons in and re­leasing them in the block bore. Disassemble the motor cylinder block. Check for piston/ block wear in the cylinder bore. Inspect the pistons, piston springs and thrust washers for excessive wear or damage. NOTE: Thrust washers may be held in place in the piston by residual oil.
19.Reassemble the pistons, springs and thrust washers into the cylinder block and set aside.
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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. NOTE: These “sealing” surfaces should be smooth in appearance without scratches, scoring, nicks or abrasions. Drag a fingernail across the surface to detect un­even wear or scratches which may not be visible.
4. Inspect the threaded check plug ports of the center section for debris or damage.
5. Inspect the motor cylinder block running sur­face for damage and wear.
6. Inspect all bearing, bushing and wear areas in the housing.
Assembly
(Motor Block)
(Center Section/Filter)
3. (See Figure 18) Install the new filter base (61)
onto the center section (57).
4. It will be necessary to clean the check plugs prior to re-assembly. Install the check plugs (56), in their correct location, into the center section (57). Tighten the check plugs accord­ing to Table 6.
5. Align the tabs on the filter cover with the slots in the filter base and carfully press the cover onto the base until the tabs snap into place. Insure the bypass plate (Figure 18) is located properly in the center section.
6. (See Figures 10 & 20) Install the motor shaft (39), pinion gear (38) and flat washers (36 &
40) into the center section (57).
7. Assemble the motor block assembly (4) onto the motor shaft (39).
8. (See Figure 20) Install the motor shaft, cen­ter section and motor block assembly into the housing so that the motor block pistons con­tact the thrust bearing race. NOTE: Hold in place and insure all pistons are still positioned correctly in the cylinder bore by confirming spring bias against the center section.
1. (See Figure 19) Turn the housing (1) so the
motor thrust bearing cavity is facing up. This will assist in the installation of the motor thrust bearing assembly (35) keeping it in the bearing cavity during installation of the center section assembly (57, Figure 17).
2. Insert the thrust bearing (35) in the housing (1). NOTE: Place the thin race of the bear­ing towards the housing bearing cavity. The thick race must face the pistons.
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9. (See Figure 16) After applying thread adhe-
sive, insert the center section mounting screws (12) while holding downward pres­sure on the center section assembly (57, Figure 20).
10.Tighten the center section mounting screws (12) to the proper torque. Refer to Table 6. NOTE: The center section must be fully seated into the pilot bore before the screws are tightened. The center section will not self
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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 bear-
ing (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 as-
sembly (4), pistons down, on top of the thrust bearing in the swashplate (19).
13.Coat the pump running surface with clean motor oil.
14.Care must be taken to prevent the scaring
or scratching of the center section sealing face during this step. Insert the shaft of the
swashplate/pump block assembly (Figure
21) into the housing while simultaneously compressing the pistons in the block. NOTE: To assist in the installation of these compo­nents, insert the assembly until 3/4 of the pump block is covered by the center section. Then slightly press the shaft end toward the center section while pushing the shaft into its bore.
15.Install the input shaft and bypass rod. See page 20.
16. Install the axle shaft, reduction gears and ex­pansion plate, if removed. Refer to page 18.
17. Install the side housing and brake. See page
17.
Figure 12.
Figure 13.
18.Fill the transaxle with new oil. See page 9.
19.Install the bypass arm and control arm. See page 15.
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Figure 14.
23
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
Figure 15.
Figure 16.
Figure 18.
Figure 19.
Figure 17.
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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.
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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.
The part reference numbers provided in each assembly procedure are keyed to the indi­vidual exploded views, and are also keyed to the complete unit exploded view on page 26.
1. Install the hydraulic components. See pages 21-25.
2. Install the input shaft and bypass rod. See page 20.
3. Install the axle shaft, reduction gears and expansion plate. See page 18.
4. Install the cog brake and side housing. See page 17.
5. Fill the transaxle with new oil. See page 9.
6. Install the bypass arm and control arm. See page 15.
7. Install the transaxle onto the vehicle.
8. Perform the purge procedures listed on page 10.
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
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. ingly.
The illustration below indicates the correct areas.
Use spar-
SEALANT APPLICATION
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
310-2200 EXPLODED VIEW
NOTES:
1. BRAKE AND CONTROL ARM CAN BE ON EITHER SIDE.
2. LH SIDE SHOWN. RH SIDE IS A MIRROR IMAGE.
ITEMS NOT SHOWN
11 - OIL, 20W50
58 - SEALANT TUBE (10.3 oz)
52 - KIT, SEAL
145 - ASSEMBLY, HUB PULLER
Figure 22. 310-2200
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310-2200 ITEMS LIST
No. DESCRIPTION No. DESCRIPTION
1 ASSEMBLY, MAIN HOUSING 47 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 .25 53 KIT, EXPANSION PLATE
2 ASSEMBLY, SIDE PLATE EXPANSION
HOUSING, SIDE SCREW, 10-32 X 1/2 (SELF-TAPPING) BUSHING, .624 X .719 X .562 54 KIT, FAN-PULLEY
BUSHING, .865 X .985 X .790 55 KIT, BRAKE ARM 3 PLATE, BYPASS ARM, PARKING BRAKE 4 ASSEMBLY, PUMP BLOCK WASHER .28 X .50 X .063
BLOCK, CYLINDER BOLT, 1/4-20 X 1 W/PATCH
PISTON BUSHING, .260 X .394 X .330
SPRING, COMPRESSION PIN, CLEVIS
WASHER, THRUST 56 CHECK PLUGS 5 SPACER 57 KIT, CENTER SECTION-FILTER 6 ASSEMBLY, MOTOR BLOCK CENTER SECTION, MACHINED 7 PLUG, 9/16-18 BUSHING, .707 X .788 X .591 8 PIN, STAINLESS, HEADLESS PLATE, BYPASS 9 HFHCS 1/4-20 X 1.25 (SELF-TAPPING) BOLT, HEX FLANGE 3/8-24 X 2.5
10 SEAL, LIP .625 X 1.000 X .250 FILTER, BASE 12 BOLT, HEX FLANGE 3/8-24 X 2.5 CHECK PLUG ASSEMBLY 13 SEAL, LIP .375 X .75 X .25 ASSEMBLY, COVER 14 RING, RETAINING .375 EXT ASSEMBLY, PUMP BLOCK 15 ROD, BYPASS 59 KIT, BYPASS ARM 16 RING, RETAINING .750 INT ARM, BYPASS 17 ARM, BYPASS RING, RETAINING .375 EX T (PUSHNUT) 18 RING, RETAINING .375 EXT (PUSHNUT) 61 KIT, FILTER 19 SWASHPLATE, TRUNNION, MACHINED FILTER, BASE 20 SEAL, LIP 18 X 32 X 7 ASSEMBLY, COVER 21 STUD 99 NUT, HEX 3/4-16 LOCK 22 PUCK, FRICTION 100 DISC, COG BRAKE 23 ARM, CONTROL 120 FAN, 10 BLADE 24 WASHER, FLAT 11/32 ID X 7/8 OD X 1/16 121 PULLEY 25 TWHCS 5/16-24 X 1.0 122 HEX LOCK NUT, 1/2-20 (NYLON INSERT) 26 NUT, HEX LOCK 5/16-24 UNJF 123 WASHER, OD SLOTTED 27 SPRING-HELICAL COMPRESSION HEX WASHER HEAD TAPPING SCREW 1/4-20 X .25 28 WASHER .591 X .787 X .040 124 ASSEMBLY, HUB, 4 STUD, 1/2-20 (30° TAPER) 29 SHAFT, INPUT 125 CAP, VENT ASSEMBLY 30 BEARING, BALL 17MM ID X 40MM OD X 12MM 126 FITTING, O-RING ASSEMBLY 31 RING, RETAINING WIRE .561 ID 127 CLAMP, PINCH, SINGLE EAR 32 SPACER 128 FITTING 33 SEAL, LIP 17 X 40 X 7 131 SHCS, 5/16-24 X 1.00 (PATCH) 34 RING, RETAINING 132 BUSHING, PILOT, 1.125 35 BEARING, THRUST 30 X 52 X 13 133 WASHER, PLASTIC 36 WASHER, FLAT 5/8 ID X 1.0 OD X .05 134 WASHER, 1.5 X .34 X .062 37 RING, RETAINING 135 SPRING, EXTENSION 38 GEAR, PINION, 13T 136 KIT, RTN ASSEMBLY
39 SHAFT, MOTOR 137 HOSE 40 WASHER, MOTOR SHAFT .71 ID X 1.16 OD X .04 138 KIT, BREATHER ASSEMBLY 41 WASHER, HT .5 ID X 1.0 OD X .032 140 PUCK, FRICTION 42 GEAR, 10T/48T 141 SPACER, FRICTION PUCK 43 GEAR, 10T JACKSHAFT 142 SPACER, .320 X .590 X .500 44 PIN, JACKSHAFT 143 SPRING, HELICAL COMPRESSION 45 RING, SPIRAL RETAINING 144 DEFLECTOR, BELT 46 GEAR, 52T BULL
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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.
Case Drain Line (Return Line): A line returning fluid from the component housing to the reservoir.
Cavitation: A concentrated gaseous condition within the fluid causing the rapid implosion of a
gaseous bubble.
Center Section: A device which acts as the valve body and manifold of the transmission.
Charge Pump: A device which supplies replenishing fluid to the fluid power system (closed loop).
Charge Pressure: The pressure at which replenishing fluid is forced into a fluid power system.
Charge Relief Valve: A pressure control valve whose primary function is to limit pressure in the
charge circuit.
Check Valve: A valve whose primary function is to restrict flow in one direction.
Closed Loop: A sealed and uninterrupted circulating path for fluid flow from the pump to the motor
and back.
Decay Rate: The ratio of pressure decay over time.
End Cap: See “Center Section”
Entrained Air: A mechanically generated mixture of air bubbles having a tendency to separate
from the liquid phase.
Gerotor: A positive displacement pump frequently used as a charge pump.
Hydraulic Motor: A device which converts hydraulic fluid power into mechanical force and motion
by transfer of flow under pressure.
Hydraulic Pump: A device which converts mechanical force and motion into hydraulic fluid power by producing flow.
Hydrostatic Pump: See “Hydraulic Pump”
Hydrostatic Transaxle: A multicomponent assembly including a gear case and a hydrostatic
transmission.
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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.
Neutral: Typically described as a condition in which fluid flow and system pressure is below that
which is required to turn the output shaft of the motor.
Pressure Decay: A falling pressure.
Priming: The filling of the charge circuit and closed loop of the fluid power system during start up,
frequently achieved by pressurizing the fluid in the inlet line.
Purging: The act of replacing air with fluid in a fluid power system by forcing fluid into all of the components and allowing the air a path of escape.
Rated Flow: The maximum flow that the power supply system is capable of maintaining at a specific operating pressure.
Scoring: Scratches in the direction of motion of mechanical parts caused by abrasive contami­nants.
Swash Plate: A mechanical device used to control the displacement of the pump pistons in a fluid power system.
System Charge Check Valve: A valve controlling the replenishing flow of fluid from a charge circuit to the closed loop in a fluid power system.
System Pressure: The pressure which overcomes the total resistance in a system, including all efficiency losses.
Valve: A device which controls fluid flow direction, pressure, or flow rate.
Variable Displacement Pump: A pump in which the displacement per revolution can be varied.
Volumetric Displacement: The volume for one revolution.
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
NOTES
32 310-2200 EZT
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
NOTES
310-2200 EZT
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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
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