Toro 72050, 72051, 72052, 72071, 72072 Service Manual

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HYDRO-GEAR 310-3000 INTEGRATED HYDROSTATIC TRANSAXLE SERV MANL

Table of Contents – Page 1 of 2

FOREWORD

DESCRIPTION AND OPERATION

INTRODUCTION GENERAL DESCRIPTION INTRODUCTION HYDRAULIC SCHEMATIC TECHNICAL SPECIFICATIONS PRODUCT IDENTIFICATION

SAFETY PERSONAL SAFETY TOOL SAFETY WORK AREA SAFETY SERVICING SAFETY

TROUBLESHOOTING

SERVICE AND MAINTENANCE EXTERNAL MAINTENANCE SERVICE AND MAINTENANCE PROCEDURES FLUIDS BRAKE MAINTENANCE RETURN TO NEUTRAL SETTING HAND CONTROL RETURN TO NEUTRAL SETTING FOOT CONTROL PURGING PROCEDURES

REPAIR GENERAL INSTRUCTIONS REQUIRED TOOLS TORQUE SPECIFICATIONS TRANSAXLE REMOVAL LIMITED DISASSEMBLY HOW TO USE THIS MANUAL BRAKE ASSEMBLY BYPASS ASSEMBLY CONTROL ARM ASSEMBLY TORQUE BRACKET ASSEMBLY FAN AND PULLEY ASSEMBLY INPUT SHAFT ASSEMBLY CHARGE PUMP ASSEMBLY LOWER HOUSING/FILTER/MANIFOLD ASSEMBLY PLANETARY DIFFERENTIAL ASSEMBLY MOTOR/CENTER SECTION/PUMP ASSEMBLY

HYDRO-GEAR 310-3000 INTEGRATED HYDROSTATIC TRANSAXLE SERV MANL

Table of Contents – Page 2 of 2

REPAIR - Continued

DIRECTIONAL CONTROL ASSEMBLY TRANSAXLE INSTALLATION ASSEMBLY AFTER A COMPLETE TEAR-DOWN

PARTS LIST

GLOSSARY OF TERMS

Table of Contents

Section Page

Foreword.............................................................................................................................. i

Description and Operation................................................................................................. 1

Introduction ........................................................................................................................ 1

General Description................................................................................................................................. 1

Introduction ............................................................................................................................................. 1

Hydraulic Schematic................................................................................................................................ 2

Technical Specifications........................................................................................................................... 3

Product Identification ............................................................................................................................... 3

Safety .................................................................................................................................. 4

Personal Safety....................................................................................................................................... 4

Tool Safety .............................................................................................................................................. 4

Work Area Safety .................................................................................................................................... 4

Servicing Safety....................................................................................................................................... 4

Troubleshooting................................................................................................................. 5

Service and Maintenance................................................................................................... 6

External Maintenance.............................................................................................................................. 6

Service and Maintenance Procedures....................................................................................................... 6

Fluids...................................................................................................................................................... 7

Brake Maintenance.................................................................................................................................. 8

Return to Neutral Setting Hand Control..................................................................................................... 9

Return to Neutral Setting Foot Control.................................................................................................... 10

Purging Procedures`............................................................................................................................... 11

Repair ................................................................................................................................ 12

General Instructions............................................................................................................................... 12

Required Tools....................................................................................................................................... 12

Torque Specifications............................................................................................................................. 12

Transaxle Removal ................................................................................................................................ 12

Limited Disassembly ............................................................................................................................. 12

How to Use This Manual........................................................................................................................ 13

Brake Assembly ................................................................................................................................ 14,15

Bypass Assembly.................................................................................................................................. 16

Control Arm Assembly ....................................................................................................................... 17,18

Torque Bracket Assembly ...................................................................................................................... 19

Fan and Pulley Assembly ...................................................................................................................... 20

Input Shaft Assembly............................................................................................................................. 21

Charge Pump Assembly ........................................................................................................................ 22

Lower Housing/Filter/Manifold Assembly................................................................................................. 23

Planetary Differential Assembly.......................................................................................................... 24,25

Motor/Center Section/Pump Assembly .......................................................................................... 26,27,28

Directional Control Assembly ................................................................................................................. 29

Transaxle Installation............................................................................................................................. 30

Assembly After a Complete Tear-down.................................................................................................... 30

Parts List ...................................................................................................................... 31,32

Glossary of Terms ....................................................................................................... 33,34

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 the 3103000Hydro-Gear Integrated Hydrostatic Transaxle (IHT). The Troubleshooting Guide order number is BLN-51095.

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 proper tools and the mechanics to 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.

Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an area where a source of ignition may be present.

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 OPE Technicians Certification of Austin, Texas or their 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 one of our Central Service Distributors, or call our Technical Service Department at (217) 728-2581.

310-3000 IHT

SECTION 1. DESCRIPTION AND OPERATION

INTRODUCTION

The purpose of this manual is to provide information useful in servicing the Hydro-Gear 3103000 Integrated Hydrostatic Transaxle (IHT). This manual includes transaxle general description, hydraulic schematic, technical specifications, product identification, safety, troubleshooting, maintenance, and repair 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 transaxle will need to be thoroughly cleaned before beginning most procedures.

Please refer to the instructions titled “How to Use This Manual” in the Repair Section for an explanation of the layout of the disassembly, inspection, and reassembly portions of this manual.

GENERAL DESCRIPTION

The 310-3000 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 10 cc per revolution, and motor with a fixed displacement of 21cc per revolution. The variable displacement pump features a cradle swashplate with a direct-proportional displacement control. Reversing the direction of the swashplate re-

verses 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 310-3000 has a self contained fluid supply and an internal filter. The fluid is drawn through the internal reservoir and feeds the fixed displacement gerotor charge pump. Excess fluid in the charge circuit is discharged over the charge relief valve and dumps back to case. Charge check valves in the center section are used to control the makeup flow of the fluid to the low pressure side of the loop.

The transaxle is filled and tested at the factory and should not require fluid or filter changes unless the fluid becomes contaminated.

A cam style, block lifting bypass is utilized in the 310-3000 to permit moving the vehicle for short distance at a maximum of 2 m.p.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 310-3000 utilizes an in-line floating disc brake controlled by a "cam" style actuating arm.

310-3000 IHT 1

Figure 1. 310-3000 Hydraulic Schematic

HYDRAULIC SCHEMATIC

Figure 1 provides an illustration of the hydraulic oil circuit. The oil supply for the hydraulic system of the 310-3000 IHT is also utilized for the lubrication of the planetary differential drive gears.

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 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 (or valve body) 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 swashplate is increased the amount of oil being pumped will increase and cause a higher RPM 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 transmission housing and must be made up in the loop. A charge pump is included on the 310-3000 IHT to supply this makeup flow. The make up flow is controlled (or directed) by the check valves. Each check valve will either be held opened or closed (depending upon the direction of vehicle operation) by the system operating pressure (closed) or by charge pressure (open) from the charge pump.

The charge pump maintains a continuous flow of oil as long as the input shaft is turning. All of the oil being pulled into the charge pump first must pass through an internal filter. Any oil not needed by the transmission for make up flow is

310-3000 IHT

discharged through the charge relief valve. The charge relief valve maintains the charge pressure at no more than 40 PSI.

The motor cylinder block mounts onto the splined motor shaft which drives the planetary differential gear/differential assembly.

The bypass feature in the 310-3000 has a mechanical lever which lifts the motor block off of the center section running surface, allowing any oil flowing from the pump block to be discharged into the housing without turning the motor.

TECHNICAL SPECIFICATIONS

Technical specifications for the 310-3000 IHT are given in Table 1.

PRODUCT IDENTIFICATION

Table 1. 310-3000 Technical Specifications

Overall Transaxle Reduction

30.15:1

Input Speeds

Maximum: 3600 RPM Minimum: 1800 RPM

Maximum Tire Diameter

23 inch; 584 mm

Axle Shaft Options

Type: Keyed Diameter: 1 inch; 25.4 mm Type: Flanged Diameter: Hub

Brake Type

Disc

The model and configuration of the 310-3000 IHT can be determined from the label shown in Figure 2.

H Y D R O - G E A R SULLIVAN, IL. U.S.A.

I IIII III I III II II

OEM Model

Number

165758 310-3000

I II IIII IIII III III I II IIII

8 328 T1 476 Made in U.S.A.

Year Built

(unique number for that model - for that day)

Weight of Unit

58 lb; 26 kg

Hydro-Gear

Number

Serial Number

Date

(Julian - day of year)

Type of Product and Build Information

Figure 2. 310-3000 Configuration Label

310-3000 IHT 3

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 310-3000 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 310-3000 IHT. 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:

Other manuals pertaining to this machine Local and shop safety rules and codes 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 hangingclothing 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.

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.

310-3000 IHT

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. 310-3000 Troubleshooting Checklist

Possible Cause

UNIT OPERATES IN ONE DIRECTION ONLY

Control linkage bent or out of adjustment Drive belt slipping or pulley damaged

Oil level low or contaminated oil Excessive loading Brake setting incorrect Loose parts Bypass assembly sticking

Air trapped in hydraulic system

Repair or replace linkage Repair or replace drive belt or pulley

Fill to proper level or change oil Reduce vehicle loading Adjust brake to proper setting Repair or replace loose parts Repair or replace valve or linkage Purge hydraulic system

Corrective Action Refer To:

UNIT IS NOISY

In many cases problems with the 310-3000 IHT are not related to a defective transmission or axle, 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 before assuming the unit is malfunctioning. Table 2 below provides a troubleshooting check list to help determine the cause of operational problems.

Control Linkage Repair, Page 17 Pulley Repair, Page 20

Fluid Maintenance, Page 7 Vehicle Specifications Brake Adjustment, Page 8 Appropriate Repair Procedure Bypass Repair, Page 16 Purging Procedure, Page 11

UNIT HAS NO/ LOW POWER

Engine RPM 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

Damaged seals, housing, or gaskets Air trapped in hydraulic system

Adjust to correct setting Repair or replace linkage Adjust brake to proper setting Repair or replace drive belt or pulley Fill to proper level or change oil Reduce vehicle loading Repair or replace valve or linkage Purge hydraulic system

UNIT OPERATING HOT

Clean off debris Adjust brake to proper setting Repair or replace cooling fan Fill to proper level or change oil Reduce vehicle loading Purge hydraulic system

TRANSAXLE LEAKS OIL

Replace damaged component Purge hydraulic system

Vehicle Specifications Control Linkage Repair, Page 17 Brake Adjustment, Page 8 Pulley Repair, Page 20 Fluid Maintenance, Page 7 Vehicle Specifications Bypass Repair, Page 16 Purging Procedure, Page 11

Brake Adjustment, Page 8 Cooling Fan Repair, Page 20 Fluid Maintenance, Page 7

Vehicle Specifications Purging Procedure, Page 11

Appropriate Repair Procedure Purging Procedure, Page 11

310-3000 IHT 5

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

Reference Table 4., Page 13 for tools required in the maintenance of the 310-3000 IHT.

Regular external maintenance of the 310-3000 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 See Figure 3, Page 7.

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 RPM to the transaxle

4. Inspect the transaxle 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 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 310-3000 is mounted on the vehicle. Any servicing beyond those given must be performed after the unit has been removed from the vehicle. Additional procedures are provided in Section 5. Repair Procedures.

310-3000 IHT

FLUIDS

FLUID CHANGE

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 210 F and an API classification of SH/ CD is recommended. A 20W-50 engine oil has been selected for use by the factory and is recommended for normal operating temperatures.

FLUID VOLUME

Fluid volume information is provided in Table 3.

FLUID LEVEL

Certain situations may require additional fluid to be added or even replaced. Refer to Figure 3 for the proper fill port and fluid level port locations. Fill the unit until fluid flows out of the fluid level port. Recheck the fluid level once the unit has been operated for approximately 1 minute. Purging may be required. Refer to the purging procedures, Page 11.

This transaxle is factory filled and does not require regular oil change. In the event of oil contamination or degradation an oil change may improve performance.

Using transaxle removal procedure from Section 5, Page 12, remove transaxle and drain oil from top fluid fill port. Fill unit per Table 3, reinstall transaxle and perform purging procedures, Page

11.

In the event fluid change and filter inspection is required, refer to Page 23, Disassembly/Assembly instructions.

Caution

Do not overfill.

If you overfill the transaxle while the unit is "cold", it may overflow as it reaches normal operating temperatures. The oil level should not be above the manufacturer’s suggestions outlined in this manual. This will allow the space needed for the oil to expand as it warms up.

Table 3. Fluid Volumes for the 310-3000 IHT

Fluid Description

20W-50 engine oil

Figure 3. 310-3000 Fluid Fill and Level Ports

Volume

0.95 gal . (116.5 oz.)

310-3000 IHT 7

BRAKE MAINTENANCE

BRAKE SETTING

1. Remove the brake arm bias spring, and then the cotter pin securing the brake castle nut.

2. Insert a 0.015" feeler gage between the brake disc and top brake puck, and then set the brake by tightening or loosening the castle nut.

RETURN TO NEUTRAL SETTING (OPTIONAL FEATURE)

The return to neutral mechanism on the transmission is designed to set the directional control into a neutral position. An optional feature, it is available in two versions. One version provides hand control, and the other, foot control. Setting procedures are provided on pages 9 and 10.

WARNING

3. Adjust brake gap to 0.015" clearance.

4. Install the cotter pin to secure the castle nut, and then install the brake arm bias spring.

POTENTIAL FOR SERIOUS INJURY

Certain procedures require the vehicle engine to be operated and the vehicle to be raised off of the ground. To prevent possible injury to the servicing technician and/or bystanders, insure the vehicle is properly secured.

310-3000 IHT

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