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
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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) (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.
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
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CYLINDER BLOCK ASSEMBLY |
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CYLINDER BLOCK ASSEMBLY |
10 CC VARIABLE |
10 CC FIXED |
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DISPLACEMENT PUMP |
FIXED DISPLACEMENT ANGLE |
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DISPLACEMENT MOTOR |
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CHECK VALVE |
CHECK VALVE |
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BYPASS ACTUATOR |
FILTER ASSEMBLY |
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RESERVOIR |
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TRANSAXLE HOUSING |
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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 |
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FAN |
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PACK |
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BELT KEEPER |
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CONTROL ARM |
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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.
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Table 1. 310-0510 Technical Specifications |
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Overall Transaxle Reduction |
Axle Shaft Options |
22.15:1 |
Type: Keyed / Double “D” |
Input Speeds |
Diameter: 0.75 inch; 19.05 mm |
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Maximum: 3000 RPM |
Brake Type |
Minimum: 1800 RPM |
Disc |
Maximum Tire Diameter |
Weight of Unit |
20 inch; 508 mm |
30 lb; 14 kg |
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PRODUCT IDENTIFICATION
The model and configuration of the 310-0510 IHT can be determined from the label shown in Figure 3.
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H Y D R O - G E A R |
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SULLIVAN, IL. |
U.S.A. |
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Model |
I IIII III |
IIII II II |
Hydro-Gear |
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1667683054 |
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3148--05102400 |
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Number |
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Ref. Number |
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I II IIII IIII III III I II IIII |
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0 319 TZ1 401 |
Made in U.S.A. |
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Year Built |
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Serial Number |
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(unique number for that model - for that day) |
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Date |
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(Julian - day of year) |
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Type of Product and Build Information |
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Figure 3. 310-0510 Configuration Label |
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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 |
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Corrective Action |
UNIT OPERATES IN ONE DIRECTION ONLY |
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Control linkage bent or out of adjustment |
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Repair or replace linkage, Page 9 |
Drive belt slipping or pulley damaged |
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Repair or replace drive belt or pulley, Page 9 |
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VEHICLE DOES NOT DRIVE/TRACK STRAIGHT |
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Vehicle tires improperly inflated |
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Refer to vehicle manufacturer suggested pressure |
Control linkage bent, loose or out of adjustment |
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Repair, adjust or replace vehicle linkage |
Bypass partially engaged |
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Adjust bypass linkage |
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UNIT IS NOISY |
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Oil level low or contaminated oil |
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Fill to proper level or change oil, Page 10 |
Excessive loading |
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Reduce vehicle loading, Page 9 |
Brake setting incorrect |
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Adjust brake to proper setting, Page 13 |
Loose parts |
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Repair or replace loose parts |
Bypass assembly sticking |
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Repair or replace valve or linkage |
Air trapped in hydraulic system |
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Purge hydraulic system, Page 11 |
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UNIT HAS NO/LOW POWER |
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Engine speed low |
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Adjust to correct setting |
Control linkage bent or out of adjustment |
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Repair or replace linkage, Page 9 |
Brake setting incorrect |
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Adjust brake to proper setting, Page 13 |
Drive belt slipping or pulley damaged |
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Repair or replace drive belt or pulley, Page 9 |
Oil level low or contaminated oil |
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Fill to proper level or change oil, Page 10 |
Excessive loading |
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Reduce vehicle loading, Page 9 |
Bypass assembly sticking |
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Repair or replace valve or linkage |
Air trapped in hydraulic system |
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Purge hydraulic system, Page 11 |
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UNIT OPERATING HOT |
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Debris buildup around transaxle |
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Clean off debris, Page 9 |
Brake setting incorrect |
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Adjust brake to proper setting, Page 13 |
Cooling fan damaged |
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Repair or replace cooling fan |
Oil level low or contaminated oil |
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Fill to proper level or change oil, Page 10 |
Excessive loading |
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Reduce vehicle loading, Page 9 |
Air trapped in hydraulic system |
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Purge hydraulic system, Page 11 |
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TRANSAXLE LEAKS OIL |
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Damaged seals, housing, or gaskets |
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Replace damaged component |
Air trapped in hydraulic system |
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Purge hydraulic system, Page 11 |
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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 |