Toro 71181, 71191, 71192, 71193, 71196 Service Manual
...
HYDRO-GEAR 310-0500/0750 SERVICE MANUAL
Table of Contents – Page 1 of 1
INTRODUCTION/GENERAL DESCRIPT ION
INTRODUCTION
GENERAL DESCRIPTION
MAINTENCE
FLUIDS/GREASES
SAFETY PRECAUTIO NS
MAINTENANCE
TROUBLESHOOTING DIAGRAM 310-500/0750 IHT
TROUBLESHOOTING DIAGRAM
MINOR REPAIRS
GENERAL INFORMATION
SHAFT SEALS
PARKING BRAKE
CONTROL ARM & FRICTION PACK
OIL LEVEL
MAJOR REPAIRS
GENERAL INFORMATION
DISASSEMBLY PRO CED URE S
DISASSEMBLY PRO CED URE S
DISASSEMBLY PRO CED URE S
DISASSEMBLY PRO CED URE S
DISASSEMBLY PRO CEDURES
RECONDITIONING AND REPLACEMENT OF PARTS
ASSEMBLY PROCEDURES
ASSEMBLY PROCEDURES
ASSEMBLY PROCEDURES
ASSEMBLY PROCEDURES
ASSEMBLY PROCEDURES
ASSEMBLY PROCEDURES
OIL FILL & START-UP PROCEDURES
310-0500 PARTS DRAWING & PARTS LIST
310-500/0750 IHT PARTS DRAWING & PARTS LIST
PARTS DRAWING & PARTS LIST 310-0500/0750 IHT
PARTS DRAWING & PARTS LIST 310-500/0750 IHT
PRODUCT LINE - HYDRO-GEAR
A WORLD LEADER IN TURF CARE TRANSMISSION PRODUCTS
Table
of
Contents
Introduction
General Description
FIuids/Greases
Safety Precautions
Maintenance
Troubleshooting Diagram
Troubleshooting Chart
Minor Repairs
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General Information
Shaft Seal
Parking Brake
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3
4
4
4
4
5
6
7-8
7
7
8
Control
Oil Level
Major Repairs
General Information
Disassembly Procedures
Reconditioning
Assembly Procedures
Oil Fill & Start-up Procedures
310-0500
310-0750
Arm
/
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Parts Drawing
Parts Drawing
Friction Pack
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&
Replacement
of
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&
Parts List
&
Parts List
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Components
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8
8
9-19
9
9-13
13
I4 - 19
19
20 - 21
22-23
Page
Product Line
2
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24
310-0500/07501HT
Introduction
The purpose
useful in servicing the Hydro-Gear Integrated Hydrostatic Transaxle (IHT). This manual includes component
description, troubleshooting, maintenance and repair
procedures.
A
transaxle normally
life of the vehicle in which it
be
required, the unit must be removed from its installed
location and thoroughly cleaned before beginning
procedures.
of
this manual is to provide information
will
not require servicing during the
is
installed. Should servicing
most
General Description
The Integrated Hydrostatic Transaxle is a
unit designed for the transfer and control of power.
provides an infinitely variable
and maximum in both forward and reverse modes of
operation.
The IHT uses a variable pump with a maximum displace-
ment of 1Occ per revolution, and a motor with a fixed
displacement of 21cc per revolution. The variable
placement pump features a cradle swashplate with a
direct-proportional displacement control. Reversing the
direction of tilt of the swashplate reverses the flow of oil
from the pump to the motor and thus reverses the
direction of the motor output rotation. The fixed displacement motor uses a
motor are of the axial piston design, and both utilize
spherical nosed pistons which are held against a thrust
race by internal compression springs.
fixed
speed
swashplate. The pump and
self
contained
range between zero
dis-
The IHT has a self-contained fluid supply and an integral
filter. The fluid
"head" on the fluid in the housing/reservoir with an assist
by the negative pressure created in the pump pistons
they operate.
Charge check valves in the center section are used to
control the makeup flow of fluid to the low pressure side
of the
loop.
The IHT is filled and tested at the factory and should
require fluid or filter changes unless the fluid becomes
contaminated.
A
cam style, block
permit moving the vehicle for short distances at a maxi-
mum of 2 mph without starting the engine.
It
Actuating the bypass
static braking capacity.
tionary and on a level surface and in neutral when
actuating the bypass.
The IHT includes an integral differential which utilizes
heavy duty heat treated bevel gears.
A
"cam" style arm is utilized to actuate an in line floating
multidisc parking brake. The brake discs are enclosed in
a cavity that
is
forced through the filter by a positive
lifting
bypass
WARNING
will
is
sealed from the oil supply.
is
utilized in the IHT to
!!!
result in the
The
machine must
loss
of
as
not
hydro-
be
sta-
IHT
Flow
310-0500/0750
Illustration
IHT
Page
3
Fluids/Greases
The fluids used in HYDRO-GEAR products have been
carefully selected, and only equivalent or better products
be
should
used.
Maintenance
Check the transaxle cooling fan for broken or distorted
blades,
tened. Replace the
and
check to
fan
see
that the fan
if
damaged.
is
securely fas-
Typically, an engine oil with a minimum rating of
at
210
F
and an
mended. A
by the factory.
The grease used in the manufacture of Hydro-Gear
products
substituted for with equivalent products only
readily available in your area.
NOTE:
types.
is a Rykon Premium grease
This grease
API
2OW-50
classification
engine oil has been selected for
of
SWCD is recom-
and
is
not compatible with all grease
55
SUS
use
should
if
it is
not
be
Safety Precautions
Certain procedures may require the vehicle to
abled
technician
(wheels
nected, etc.) in order to prevent possible injury to the
Some cleaning solvents are flammable.
sible fire, do not use cleaning solvents in an area where
a source of ignition may be present.
raised off the ground, engine discon-
and
bystanders.
To
be
avoid
dis-
pos-
NOTE:
refer
Keep
effect the cooling efficiency of the fins on the housing.
Avoid high pressure washing, compressed air is the
preferred method
Inspect
to stop the vehicle or hold on a
are necessary. You should also make sure it
gages
Check to make sure the bypass actuator and linkage
operational. The bypass must be fully released during
operation of the vehicle.
Inspect
the housing.
Check the oil level and add oil as necessary to bring it up
to the proper level.
Not all vehicles are equipped with a cooling fan,
to
your vehicle manual.
the transaxle clean. Grass clippings and dirt will
of
removing loose debris.
the brake for proper operation.
30%
when the
the transaxle for leaks at lip seals or damage to
pedal
is
released.
If
the brake fails
slope, adjustments
fully
disen-
is
loss
The
loss
tenance
develop.
of hydrostatic driveline power may result in the
of hydrostatic braking capacity. Proper brake main-
becomes
very important should
this
condition
310-0500
Page
4
Integrated
Hydrostatic
Transaxle
310-0500/0750
IHT
OPERATES
IN
ONE DIRECTION ONLY
CHECK CONTROL OK CHECK DRIVE BELT
LINKAGE EXCESSIVE PULLEY SLIPPAGE REPLACE
I
DEFECTIVE
LOW
PROPER LEVEL
CONDITION
DEFECTIVE DEFECTIVE DEFECTIVE HIGH
FOR
OK
REPAIR OR
I
I
DEFECTIVE
REPLACE
OPERATING
DEFECTIVE
FOR
EXCESSIVE DRIVE BELT VEHICLE LOAD
DEBRIS BUILDUP
IG
HOT/ LOSING POWER
DEFECTIVE
I
PROPER SETTING
LINKAGE
*
CHANGE OIL
LEVEL
FILL TO
DEFECTIVE
DEBRIS REPLACE
REPLACE
TRANSAXLE
NOISY
IN UNIT VALVE LINKAGE
VEHICLE LOAD
HIGH
VEHICLE LOAD
I
I
VEHICLE LOAD
UNDER LOAD
DEFECTIVE DEFECTIVE
I
TO PROPER
TRANSAXLE REPAIR
OR
LINKAGES AND METAL TO
METAL
BYPASS VALVE
CONTACT POINTS
I
ADJUST
LINKAGE
I
If
*
REWIRE TRANSAXLE REMOVAL
Page
5
THE ENGINE DISABLED BEFORE PERFORMING ANY ADJUSTMENTS
SYMPTOM
WARNING!!!
THE VEHICLE SHOULD BE ON LEVEL GROUND AND
-
OPERATES
IN
ONE DIRECTION ONLY
POSSIBLE CAUSE
-Inspect control linkage
&
-Inspect drive belt
pulleys
SYMPTOM - NOISY
POSSIBLE CAUSE
-Check oil level & condition
-Check for excessive loading
-Check brake setting
-Check for loose parts
-Check bypass valve linkage operation
SYMPTOM - LOW POWER
POSSIBLE CAUSE
-Check engine
-Check drive belt & pulleys
-Check oil level
-Check for excessive loading
-Check brake setting
-Check for loose parts
-Check bypass valve linkage operation
RPM
&
condition
CORRECTIVE ACTION
-Repair or replace
-Repair or replace
CORRECTIVE ACTION
-Fill
to proper level or change oil
-Reduce vehicle loading
-Adjust brake to proper setting
-Repair or replace loose parts
-Repair or replace linkage
CORRECTIVE ACTION
-Adjust to correct setting
-Repair or replace
-Fill to proper level or change oil
-Reduce vehicle loading
-Adjust brake to proper setting
-Repair or replace loose parts
-Repair or replace linkage
SYMPTOM - OPERATING HOT
POSSIBLE CAUSE
-Check for debris buildup
-Check oil level
-Check for excessive loading
-Check brake setting
Page
6
&
condition
CORRECTIVE ACTION
-Clean
-Fill to proper level or change oil
-Reduce vehicle loading
-Adjust brake to proper setting
off
debris
31
0-0500/0750
IHT
Minor Repairs
General Information
Minor Repairs may
dures in this section, without voiding the unit warranty.
Cleanliness is a primary means of assuring satisfactory
life of either new or repaired units. Cleaning parts by
using solvent wash and air drying is usually adequate.
with any precision equipment,
of foreign materials and chemicals.
Protect all exposed sealing surfaces and open cavities
from damage and foreign material. The outer surfaces
the transaxle should be cleaned before beginning any
repairs.
be
performed, following the proce-
all
parts must
be
kept free
To remove the input shaft seal carefully pull the seal
of the housing bore with a “hook” type tool or a slide
hammertype puller. Care must
to the housing bore or to the shaft sealing surface.
Lubricate the new seal prior to installation with a petro-
As
leum jelly.
Wrap
cellophane tape to prevent damage to the new seal lip
during installation.
of
Slide the seal over the shaft and press
bore. Be careful not to damage the seal. The seal should
seat against the retaining ring.
be
taken to avoid damage
the shaft spline (keyway) with a thin plastic or
it
into the housing
out
Shaft
Lip type seals are used on the pump input shaft, the
displacement control shaft and the bypass actuator shaft
of the transaxle. These seals can be replaced without
major disassembly
seals generally requires removal of the transaxle from
the machine frame.
Seals
of
the unit. Replacement of these
The
actuator shaft seal may be replaced following similar
procedures.
displacement control shaft seal and the bypass
Input
Shaft
3100500/7501HT
Seal
Removal
Input
Shaft
Seal
Installation
Page?
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