Toro 71223, 71227, 71228, 71233, 71242 Service Manual
...
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 PROCEDURES
RETURN TO NEUTRAL SETTING
BRAKE MAINTENANCE
FRICTION PACK ADJUSTMENT
SECTION 5 REPAIR
HOW TO USE THIS SECTION
GENERAL INSTRUCTIONS
TRANSAXLE REMOVAL
LIMITED DISASSEMBLY
TOOLS AND TORQUES
BRAKE ASSEMBLY AND BYPASS ARM
CONTROL ARM AND FRICTION PACK
SEAL KIT REPLACEMENT
SIDE HOUSING
AXLE SHAFT, DIFFERENTIAL AND REDUCTION GEARS
MOTOR SHAFT AND BYPASS ROD
INPUT SHAFT
HYDRAULIC COMPONENTS
TRANSAXLE INSTALLATION
ASSEMBLY AFTER A COMPLETE TEARDOWN
SEALANT APPLICATION
310-0710 IHT
DESCRIPTION
FEATURES
TRANSAXLE REMOVAL
PARTS LIST
GLOSSARY OF TERMS
We set the wheels in motion.
310-0510
Integrated Hydrostatic Transaxle
Service and Repair Manual
BLN-51260
October 2001
Table of Contents
Section Page
Foreword ........................................................................................................................................ 1
Section 1 Description and Operation ........................................................................................... 2
Introduction ........................................................................................................................................................2
General Description ............................................................................................................................................ 2
Hydraulic Schematic ........................................................................................................................................... 3
External Featur es 310-0510 ...............................................................................................................................4
Model Recognition ..............................................................................................................................................5
Technical Specifications .....................................................................................................................................6
Product Identification ..........................................................................................................................................6
Section 2 Safety ............................................................................................................................. 7
Personal Safety .................................................................................................................................................. 7
Tool Safety ......................................................................................................................................................... 7
Work Area Safety ...............................................................................................................................................7
Servicing Safety .................................................................................................................................................7
Section 3 Troubleshooting ...........................................................................................................8
Section 4 Service and Maintenance ............................................................................................. 9
External Maintenance ......................................................................................................................................... 9
Service and Maintenance Procedures ................................................................................................................9
Fluids .................................................................................................................................................................9
Fluid Change .................................................................................................................................................... 10
Purging Procedures .......................................................................................................................................... 11
Return to Neutral Setting .................................................................................................................................. 12
Brake Maintenance .......................................................................................................................................... 13
Friction Pack Adjustment .................................................................................................................................. 13
Section 5 Repair ..........................................................................................................................14
How To Use This Section .................................................................................................................................14
General Instructions ......................................................................................................................................... 14
Transaxle Removal .......................................................................................................................................... 14
Limited Disassembly ......................................................................................................................................... 14
Tools and Torques ........................................................................................................................................... 15
Brake Assembly and Bypass Arm ..................................................................................................................... 16
Control Arm and Friction Pack .......................................................................................................................... 17
Seal Kit Replacement ......................................................................................................................................18
Side Housing .................................................................................................................................................... 19
Axle Shaft, Differential and Reduction Gears ....................................................................................................20
Motor Shaft and Bypass Rod ............................................................................................................................ 21
Input Shaft ........................................................................................................................................................ 22
Hydraulic Components ................................................................................................................................ 23-26
Transaxle Installation ........................................................................................................................................ 27
Assembly After a Complete Teardown .............................................................................................................. 27
Sealant Application .....................................................................................................................28
310-0710 IHT ................................................................................................................................29
Description ....................................................................................................................................................... 29
Features ........................................................................................................................................................... 29
Transaxle Removal .......................................................................................................................................... 29
Parts List .................................................................................................................................30-33
Glossary of Terms .................................................................................................................. 34-35
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 310-0510
Integrated Hydrostatic Transaxle (IHT). The
Troubleshooting Manual for the 310-0510 is
part number BLN-51261. Troubleshooting for
the 310-0510 is further illustrated in vi deo BLN51368 (NTSC).
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!
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.
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) (610) 363-3844 or their Hydro-Gear Distributor. Many distributors will be hosting
certification testing. These study 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.
It is necessary, and good shop practice, that
your service area be equipped with the proper
310-0510 IHT 1
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. 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.
GENERAL DESCRIPTION
The 310-0510 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.
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
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 310-0510 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 makeup flow of the fluid to the low
pressure side of the loop.
A check ball lifting bypass is utilized in the 3100510 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
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.
The 310-0510 utilizes an in-line floating disc
brake controlled by a “cam” style actuating arm.
Figure 1. 310-0510 Hydraulic Schematic
310-0510 IHT 2
VARIABLE SWASH PLATE
INPUT SHAFT
CYLINDER BLOCK ASSEMBLY
10 CC VARIABLE
DISPLACEMENT PUMP
CHECK VALVE
BYPASS ACTUATOR
RESERVOIR
TRANSAXLE HOUSING
Figure 2. 310-0510 Hydraulic Flow Illustration
10 CC FIXED
DISPLACEMENT MOTOR
CHECK VALVE
FILTER ASSEMBLY
HYDRAULIC SCHEMATIC
Figure 2 provides an illustration of the hydraulic
oil circuit. The oil supply for the hydraulic
system of the 310-0510 IHT 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 swashplate will reverse the direction of
oil flow.
CYLINDER BLOCK ASSEMBLY
FIXED DISPLACEMENT ANGLE
DIFFERENTIAL ASSEMBLY
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 310-0510 has a
mechanical lever which lifts the check valve
balls off their seat. This allows oil flow from the
cylinder blocks to be discharged.
During the operation of the transaxle, fluid is
“lost” from the hydraulic loop through leak paths
310-0510 IHT 3
EXTERNAL FEATURES 310-0510
FRICTION
PACK
Friction Pack Option
BELT KEEPER
CONTROL ARM
BRAKE ARM
BYPASS ARM
AXLE CLIP
FAN
BRAKE
DISC
Return to Neutral Option
FILL PORT
AXLE CLIP
ADJUSTING
PUCK
AXLE SHAFT
AXLE CLIP
EXPANSION
TANK
INPUT SHAFT
AXLE CLIP
310-0510 IHT 4
MODEL RECOGNITION
618-0319 166768 104-1760
173839 036932 618-0389A
310-0510 IHT 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
Input Speeds
Maximum: 3000 RPM
Minimum: 1800 RPM
Maximum Tire Diameter
20 inch; 508 mm
Axle Shaft Options
Type: Keyed / Double “D”
Diameter: 0.75 inch; 19.05 mm
Brake Type
Disc
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.
H Y D R O - G E A R
H Y D R O - G E A R
SULLIVAN, IL. U.S.A.
SULLIVAN, IL. U.S.A.
I IIII III IIII II II
I IIII III IIII II II
Model
Model
Number
Number
Year Built
Year Built
Date
Date
(Julian - day of year)
(Julian - day of year)
166768
13054 318-2400
13054 318-2400
I II IIII IIII II I III I II IIII
I II IIII IIII II I III I II IIII
0 319 Z1 401 Made in U.S.A.
0 319 Z1 401 Made in U.S.A.
Type of Product and Build Information
Type of Product and Build Information
314-0510
T
Serial Number
Serial Number
(unique number for that model - for that day)
(unique number for that model - for that day)
Figure 3. 310-0510 Configuration Label
Hydro-Gear
Hydro-Gear
Ref. Number
Ref. Number
310-0510 IHT 6
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 310-0510
IHT, 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 slipproof 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 310-0510 IHT.
This section addresses some of these
precautions but must not be considered an allinclusive 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.
Proper brake maintenance is very important
should this condition develop.
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.
310-0510 IHT 7
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!
Table 2. 310-0510 Troubleshooting Checklist
UNIT OPERATES IN ONE DIRECTION ONLY
Control linkage bent or out of adjustment
Drive belt slipping or pulley damaged
VEHICLE DOES NOT DRIVE/TRACK STRAIGHT
Vehicle tires improperly inflated
Control linkage bent, loose or out of adjustment
Bypass partially engaged
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. Be sure to perform
all operational checks and adjustments outlined
in Section 4, Service and Maintenance before
assuming the unit is malfunctioning. Table 2
below provides a troubleshooting check list to
help determine the cause of operational problems.
Corrective Action Possible Cause
Repair or replace linkage, Page 9
Repair or replace drive belt or pulley, Page 9
Refer to vehicle manufacturer suggested pressure
Repair, adjust or replace vehicle linkage
Adjust bypass linkage
Oil level low or contaminated oil
Excessive loading
Brake setting incorrect
Loose parts
Bypass assembly sticking
Air trapped in hydraulic system
Engine speed low
Control linkage bent or out of adjustment
Brake setting incorrect
Drive belt slipping or pulley damaged
Oil level low or contaminated oil
Excessive loading
Bypass assembly sticking
Air trapped in hydraulic system
Debris buildup around transaxle
Brake setting incorrect
Cooling fan damaged
Oil level low or contaminated oil
Excessive loading
Air trapped in hydraulic system
UNIT IS NOISY
Fill to proper level or change oil, Page 10
Reduce vehicle loading, Page 9
Adjust brake to proper setting, Page 13
Repair or replace loose parts
Repair or replace valve or linkage
Purge hydraulic system, Page 11
UNIT HAS NO/LOW POWER
Adjust to correct setting
Repair or replace linkage, Page 9
Adjust brake to proper setting, Page 13
Repair or replace drive belt or pulley, Page 9
Fill to proper level or change oil, Page 10
Reduce vehicle loading, Page 9
Repair or replace valve or linkage
Purge hydraulic system, Page 11
UNIT OPERATING HOT
Clean off debris, Page 9
Adjust brake to proper setting, Page 13
Repair or replace cooling fan
Fill to proper level or change oil, Page 10
Reduce vehicle loading, Page 9
Purge hydraulic system, Page 11
Damaged seals, housing, or gaskets
Air trapped in hydraulic system
TRANSAXLE LEAKS OIL
Replace damaged component
Purge hydraulic system, Page 11
310-0510 IHT 8
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.
2. Check oil level in accordance with Figure 4
Page 10.
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 transmission cooling fan for
broken or distorted blades and remove any
obstructions (grass clippings, leaves, dirt,
etc.).
5. Inspect the axle parking brake and vehicle
linkage to insure proper actuation and
adjustment of the parking brake.
mentioned in the repair section of this manual
must be performed after the unit has been
removed from the vehicle.
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 at 212°F (100° C) and an API classification of SL is recommended. A 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.
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 310-0510 to the top of the oil fill port.
Recheck the fluid level once the unit has been
operated for approximately 1 minute.
Purging may be required. Refer to the purging
procedures on page 11.
6. Inspect the vehicle control linkage to the
directional control arm on transaxle. Also,
insure the control arm is securely fastened
to the trunnion arm of the transaxle.
7. Inspect the bypass mechanism on the
transaxle and vehicle linkage to insure it
actuates and releases fully.
SERVICE AND MAINTENANCE
PROCEDURES
All the service and maintenance procedures
presented on the following pages can be
performed while the 310-0510 is mounted on
the vehicle. Any repair procedures as
310-0510 IHT 9
Loading...