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 Features 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 video 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!

It is necessary, and good shop practice, that your service area be equipped with the proper

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) [phone] 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 [phone].

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

2	310-0510 IHT

INPUT SHAFT

VARIABLE SWASH PLATE

	CYLINDER BLOCK ASSEMBLY
		CYLINDER BLOCK ASSEMBLY
10 CC VARIABLE	10 CC FIXED
DISPLACEMENT PUMP		FIXED DISPLACEMENT ANGLE
	DISPLACEMENT MOTOR
CHECK VALVE	CHECK VALVE
BYPASS ACTUATOR	FILTER ASSEMBLY
RESERVOIR
TRANSAXLE HOUSING		DIFFERENTIAL ASSEMBLY

Figure 2. 310-0510 Hydraulic Flow Illustration

HYDRAULIC SCHEMATIC

Figure 2 provides an illustration of the hydraulic oil circuit. 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.

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 310-0510 has a mechanical lever which lifts the check valve balls off their seat. This allows oil flow from the cylinder blocks to be discharged.

310-0510 IHT

3

EXTERNAL FEATURES 310-0510

FRICTION						FAN
PACK
				BELT KEEPER
			CONTROL ARM

BRAKE ARM

BRAKE

DISC

BYPASS ARM

Friction Pack Option

AXLE CLIP

AXLE SHAFT

AXLE CLIP

ADJUSTING

PUCK

Return to Neutral Option

FILL PORT

AXLE CLIP

EXPANSION

TANK

INPUT SHAFT

AXLE CLIP

4	310-0510 IHT

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	Axle Shaft Options
22.15:1	Type: Keyed / Double “D”
Input Speeds	Diameter: 0.75 inch; 19.05 mm
Maximum: 3000 RPM	Brake Type
Minimum: 1800 RPM	Disc
Maximum Tire Diameter	Weight of Unit
20 inch; 508 mm	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
		SULLIVAN, IL.		U.S.A.
	Model	I IIII III	IIII II II		Hydro-Gear
		1667683054		3148--05102400
	Number				Ref. Number
		I II IIII IIII III III I II IIII
		0 319 TZ1 401		Made in U.S.A.
	Year Built			Serial Number
			(unique number for that model - for that day)
	Date
	(Julian - day of year)
		Type of Product and Build Information
		Figure 3. 310-0510 Configuration Label

6	310-0510 IHT

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.

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.

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.

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!

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.

Table 2. 310-0510 Troubleshooting Checklist

Possible Cause		Corrective Action
UNIT OPERATES IN ONE DIRECTION ONLY
Control linkage bent or out of adjustment		Repair or replace linkage, Page 9
Drive belt slipping or pulley damaged		Repair or replace drive belt or pulley, Page 9
VEHICLE DOES NOT DRIVE/TRACK STRAIGHT
Vehicle tires improperly inflated		Refer to vehicle manufacturer suggested pressure
Control linkage bent, loose or out of adjustment		Repair, adjust or replace vehicle linkage
Bypass partially engaged		Adjust bypass linkage
	UNIT IS NOISY
Oil level low or contaminated oil		Fill to proper level or change oil, Page 10
Excessive loading		Reduce vehicle loading, Page 9
Brake setting incorrect		Adjust brake to proper setting, Page 13
Loose parts		Repair or replace loose parts
Bypass assembly sticking		Repair or replace valve or linkage
Air trapped in hydraulic system		Purge hydraulic system, Page 11
UNIT HAS NO/LOW POWER
Engine speed low		Adjust to correct setting
Control linkage bent or out of adjustment		Repair or replace linkage, Page 9
Brake setting incorrect		Adjust brake to proper setting, Page 13
Drive belt slipping or pulley damaged		Repair or replace drive belt or pulley, Page 9
Oil level low or contaminated oil		Fill to proper level or change oil, Page 10
Excessive loading		Reduce vehicle loading, Page 9
Bypass assembly sticking		Repair or replace valve or linkage
Air trapped in hydraulic system		Purge hydraulic system, Page 11
UNIT OPERATING HOT
Debris buildup around transaxle		Clean off debris, Page 9
Brake setting incorrect		Adjust brake to proper setting, Page 13
Cooling fan damaged		Repair or replace cooling fan
Oil level low or contaminated oil		Fill to proper level or change oil, Page 10
Excessive loading		Reduce vehicle loading, Page 9
Air trapped in hydraulic system		Purge hydraulic system, Page 11
TRANSAXLE LEAKS OIL
Damaged seals, housing, or gaskets		Replace damaged component
Air trapped in hydraulic system		Purge hydraulic system, Page 11

8	310-0510 IHT

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:

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 classi-

1.Check the vehicle operator’s manual for fication of SL is recommended. A 20W-50 en- the recommended load ratings. Insure gine oil has been selected for use by the fac-

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.

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

tory 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.

310-0510 IHT

9