Toro 74401, 74405, 74406, 74407, 74501 Service Manual
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We set the wheels in motion.®
310-2400/2600
Integrated Zero-Turn Transaxle
Service and Repair Manual
BLN-51134
January 2004
Table of Contents
Section Page
Foreword.........................................................................................................................................1
Section 1 Description and Operation ...........................................................................................2
Introduction........................................................................................................................................................ 2
General Description............................................................................................................................................ 2
Hydraulic Schematic........................................................................................................................................... 3
Hydraulic Flow.................................................................................................................................................... 4
External Features 310-2400L .............................................................................................................................6
External Features 310-2600R.............................................................................................................................7
Technical Specifications ..................................................................................................................................... 8
Product Identification..........................................................................................................................................8
Section 2 Safety .............................................................................................................................9
Personal Safety.................................................................................................................................................. 9
Tool Safety......................................................................................................................................................... 9
Work Area Safety ...............................................................................................................................................9
Servicing Safety ................................................................................................................................................. 9
Section 3 Troubleshooting..........................................................................................................10
Section 4 Service and Maintenance ...........................................................................................11
External Maintenance.......................................................................................................................................11
Service and Maintenance Procedures .............................................................................................................. 11
Fluids ............................................................................................................................................................... 12
Purging Procedures.......................................................................................................................................... 13
Return to Neutral Setting ..................................................................................................................................14
Brake Maintenance ..........................................................................................................................................15
Friction Pack Adjustment ..................................................................................................................................15
Section 5 Repair...........................................................................................................................16
How To Use This Section................................................................................................................................. 16
General Instructions ......................................................................................................................................... 16
Transaxle Removal .......................................................................................................................................... 16
Limited Disassembly.........................................................................................................................................16
Tools and Torques ........................................................................................................................................... 17
Back Cover ......................................................................................................................................................18
Brakes......................................................................................................................................................... 19-20
Brake Shaft & Bevel Gear................................................................................................................................. 21
Axle Shaft & Spur Gear ...............................................................................................................................22-23
Lower Housing and Filter.............................................................................................................................24-25
Motor Shaft & Bevel Gear................................................................................................................................. 26
Center Section, Cylinder Blocks and Bypass ...............................................................................................27-28
Input Shaft & Trunnion Arm ......................................................................................................................... 29-30
Transaxle Installation........................................................................................................................................ 31
Assembly After a Complete Teardown..............................................................................................................31
Sealant Application......................................................................................................................32
Parts List..................................................................................................................................34-37
Glossary of Terms ..................................................................................................................38-39
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
Hydro-Gear 310-2400, referred to as the
Integrated Zero Turn (IZT), and 310-2600
Charged IZT.
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.
Some repair procedures require that the IZT 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.
310-2400/2600 IZT 1
SECTION 1. DESCRIPTION AND OPERATION
INTRODUCTION
The purpose of this manual is to provide
information useful in servicing the Hydro-Gear
Integrated Zero Turn (IZT) transaxle. This manual includes the IZT’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.
GENERAL DESCRIPTION
The 310-2400/2600 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 21cc per revolution. The variable displacement pump features a cradle 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 310-2400/2600 has a self contained fluid
supply and an internal filter. The 310-2400 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 3102600 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.
The check valves in the 310-2400/2600 center
section are used to control the makeup flow of
the fluid to the low pressure side of the loop.
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.
A bypass is utilized in the 310-2400/2600 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. The 310-2400/2600 is configured for both floating disc and cog style parking brakes.
2
310-2400/2600 IZT
310-2400
310-2600
or
or
or
or
or
or
Figure 1. 310-2400 /2600 Hydraulic Flow Schematics
310-2400/2600 IZT 3
310-2400
INPUT
SHAFT
VARIABLE
SWASHPLATE
CYLINDER
BLOCK
ASSEMBLY
VARIABLE
DISPLACEMENT
10cc PUMP
TRANSAXLE
HOUSING
RESERVOIR
FILTER
CHECK VALVE
CHECK VALVE
BYPASS
ACTUATOR
CYLINDER BLOCK
ASSEMBLY
FIXED
SWASHPLATE
FIXED
DISPLACEMENT
21cc MOTOR
MOTOR
SHAFT
310-2600
INPUT
SHAFT
VARIABLE
SWASHPLATE
CYLINDER
BLOCK
ASSEMBLY
VARIABLE
DISPLACEMENT
10cc PUMP
TRANSAXLE
HOUSING
RESERVOIR
CHARGE
PUMP
CHECK VALVE
CHECK VALVE
FILTER
BYPASS
ACTUATOR
Figure 2. 310-2400 /2600Hydraulic Flow Illustration
CYLINDER BLOCK
ASSEMBLY
FIXED
SWASHPLATE
FIXED
DISPLACEMENT
21cc MOTOR
MOTOR
SHAFT
4
310-2400/2600 IZT
HYDRAULIC SCHEMATIC
Figure 2 provides an illustration of the hydraulic
oil circuits. The oil supply for the hydraulic
system of the 310-2400 IZT and charged 310-
2600 IZT 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.
A charge pump is included on the IZT 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
discharged through the charge relief valve. The
charge relief valve maintains the charge
pressure at no more than 40 PSI (2.76 bar).
The bypass feature in the 310-2600 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.
Oil is forced through the filter by low inlet pressure only on the 310-2400, but is pulled by a
charge pump circuit on the 310-2600.
310-2400/2600 IZT 5
EXTERNAL FEATURES 310-2400L
Back Cover
Back Cover
Axle Shaft
Disc Brake Assembly
Fill Port
Input Shaft
Hub
Assembly
Bypass
Actuator
Cog Brake Assembly
6
Seal Plug
Lower Cover
Control Arm
Assembly
310-2400/2600 IZT
EXTERNAL FEATURES 310-2600R
Filter Charge Cover
Back Cover
Axle Shaft
Charge Cover
Back Cover
Bypass
Oil Drain
Filter
Bypass
Control Arm
Assembly
Charge Cover
Charge Cover
Input Shaft
Lower Cover
Charge Cover
Fill Port
Seal Plug
Hub
Assembly
Filter
Cog Brake Assembly
“Only”
310-2400/2600 IZT 7
H Y D R O - G E A R
SULLIVAN, IL. U.S.A.
I IIII III IIII II II
13054 318-2400
I II IIII IIII III III I II IIII
0 319 Z1 401 Made in U.S.A.
Ye a r B u ilt
Date
(Julian - day of year )
Type of Product and Build Information
Serial Number
(unique nu m ber for that model - for that day)
Model
Number
Hydro-Gear
Ref. N umber
H Y D R O - G E A R
SULLIVAN, IL. U.S.A.
I IIII III IIII II II
13054 318-2400
I II IIII IIII III III I II IIII
0 319 Z1 401 Made in U.S.A.
Ye a r B u ilt
Date
(Julian - day of year )
Type of Product and Build Information
Serial Number
(unique nu m ber for that model - for that day)
Model
Number
Hydro-Gear
Ref. N umber
TECHNICAL SPECIFICATIONS
210-2400
Overall Transaxle Reduction
19.2:1
Input Speeds
Maximum: 3000 RPM
Minimum: 1800 RPM
Tire Diameter
18 in maximum; 45.7cm with 325 lbs; 147.4 kg
maximum weight on tires
210-2600
Overall Transaxle Reduction
19.2:1
Input Speeds
Maximum: 3400 RPM
Minimum: 1800 RPM
Tire Diameter
20 in maximum; 45.7cm with 325 lbs; 147.4 kg
maximum weight on tires
Axle Shaft Options
Type: Keyed / Double “D”
Diameter: 0.984 inch; 25.0 mm
Type: Flanged
Diameter: Hub
Brake Type
Disc, Parking
Cog, Parking
Weight of Unit
30 lb; 13.6 kg
Axle Shaft Options
Type: Keyed / Double “D”
Diameter: 0.984 inch; 25.0 mm
Type: Flanged
Diameter: Hub
Brake Type
Cog, Parking
Weight of Unit
31 lb; 14 kg
PRODUCT IDENTIFICATION
The model and configuration of the 310-2400/2600 IZT can be determined from the label shown in
Figure 3.
Model
Number
8
Year Built
Date
(Julian—day of year)
Table 1. 310-2400/2600 Technical Specifications
7 8 8 7 8
3
Type of Product Build Information
Figure 3. 310-2600 Configuration Label
313 - 2600L
318-2600L
Serial Number
(Unique number for that model—for that day)
Hydro-Gear
Ref. Number
310-2400/2600 IZT
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 310-2400
IZT, 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 310-2400 IZT.
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.
310-2400/2600 IZT 9
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. 310-2400 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 3102400/2600 IZT 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 11
Repair or replace drive belt or pulley, Page 11
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
Filter clogged with debris
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
Filter clogged with debris
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 12
Reduce vehicle loading, Page 11
Adjust brake to proper setting, Page 15
Repair or replace loose parts
Repair or replace valve or linkage
Purge hydraulic system, Page 13
Replace filter, Page 12
UNIT HAS NO/LOW POWER
Adjust to correct setting
Repair or replace linkage, Page 11
Adjust brake to proper setting, Page 15
Repair or replace drive belt or pulley, Page 11
Fill to proper level or change oil, Page 12
Reduce vehicle loading, Page 11
Repair or replace valve or linkage
Purge hydraulic system, Page 13
Replace filter, Page 12
UNIT OPERATING HOT
Clean off debris, Page 11
Adjust brake to proper setting, Page 15
Repair or replace cooling fan
Fill to proper level or change oil, Page 12
Reduce vehicle loading, Page 11
Purge hydraulic system, Page 13
Damaged seals, housing, or gaskets
Air trapped in hydraulic system
10
TRANSAXLE LEAKS OIL
Replace damaged component
Purge hydraulic system, Page 13
310-2400/2600 IZT
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 310-2400
IZT 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 and quality in accordance
with Figure 4 Page 12.
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.
SERVICE AND MAINTENANCE
PROCEDURES
All the service and maintenance procedures
presented on the following pages can be
performed while the 310-2400/2600 is mounted
on the vehicle. Any repair procedures as
mentioned in the repair section of this manual
must be performed after the unit has been
removed from the vehicle.
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.
310-2400/2600 IZT 11
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