310-0510/-0610/-0710 Integrated Hydrostatic Transaxle
Contents
1. 173839 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 Diameter 0 75 inch 19 05 mm Input Speeds Maximum 3000 RPM Brake Type Minimum 1800 RPM Disc Maximum Tire Diameter Weight of Unit 20 inch 508 mm 30 Ib 14 kg PRODUCT IDENTIFICATION The model and configuration of the 310 0510 IHT can be determined from the label shown in Figure 3 HYDRO GEAR SULLIVAN IL U S A Model Hydro Gear EI HH HUE HL THE TE 0 319 T1 401 Made in U S A SerialNumber Year Buil 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 aA 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 A WARNING POTENTIAL FOR SERIOUS INJURY Inattention to proper safety operation or maintenance procedures could result i2. Remove the flat washer 73 and control arm 18 Remove the inner wedge puck 90 Removal of the friction pack wedge 81 should not be necessary Note If it is re moved mark the orientation of the wedge for ease in reassembly If necessary remove and replace the fric tion pack stud 76 INSPECTION 1 2 Inspect the friction pack assembly compo nents for wear or damage Inspect the control arm for wear or damage 3 4 Inspect the inner wedge puck 90 Inspect the friction pack stud 76 for wear or damage ASSEMBLY 1 Install the friction pack stud 76 if removed Torque according to specifications in Table 9 If previously removed install the friction pack wedge 81 and self tapping bolt 88 Refer to Table 5 for bolt torque specifica tions Use the marks made during disas sembly to reposition the wedge properly Install the inner wedge puck 90 Install the control arm 18 Install the flat washer 73 and control arm screw 16 Note Remember to apply thread adhesive to the screw threads before installation Refer to Table 5 for screw torque specifications Install the puck 77 washer clip 82 spacer 79 spring 78 flat washer 73 and a new lock nut 80 Adjust the friction pack according to instructions on page 13 Install the brake assembly See page 16 76 81 88 Figure 9 Control Arm amp Friction Pack 310 0510 IHT 17 SEAL K
3. We set the wheels in motion 310 0510 0610 0710 Integrated Hydrostatic Transaxle Service and Repair Manual BLN 51260 April 2008 Table of Contents Section Page ae er Deere ae ae 1 Section 1 Description and Operation naeh 2 Introduction am Ems 2 General DESH POM 2 Fly UI EE LEE 3 Extermal Eeatures 310 0510 Pr ce Ea ceterae oce RET Rd Me ERE EX SER Repo Re a ERE deed 4 MOdelRECOGMITION pete 5 Technical Specifications srr RSs e a Bena Saran SR 6 Product Identification EE ASA AERA BA EASA ARE 6 e Tel Log 2 Safety E 7 Personal Safety Rue Ren GE IMEEM 7 TOOS nie 7 Work Area Safety u SRA ene eem er e HU I PEE D 7 Servicing Safety d eR RUD E 7 Section 3 ee 8 Section 4 Service and Maintenance esses 9 External E UE le 9 Service and Maintenance Procecdures 9 Fluid EE 9 Fluid Change 10 Purging See eet teafa 11 Return to Neutral Setting u eek m e nern nen 12 Brake Maintenance ni ine aa AEN ee 13 Friction Pack Adjustment uiii 13 Section Repair ak 14 How To Use This Section x nio eee ta ine AE 14 Genieral Instr ctlons tr Ee
4. de Eve tee 14 MP DDR 14 Limited Disassembly nece ten etae ie teh ie eae iat tides 14 HOOIS ANG Neie 15 Brake Assembly and Bypass neat teeth de 16 G ntrol Arm and Erictiom ttt near e e en dn 17 oealKit net ttt nah in 18 Side Housing itt etd nna eda par tct dete 19 Axle Shaft Differential and Reduction Gears 20 Motor Shat and Bypass Rod oem SE pede ee cc pete de ELS 21 EE 22 Hydraulic Components EE 23 26 Tiransaxle Installatiori teet d e u edle dedans tergo det i 27 Assembly After a Complete 27 Sealant Application meer Rm 28 310 0610 amp 310 0710 IHT KEE 29 Description EE 29 E Galles ert ftum a odes det nu toad ule rennen os robe 29 Transaxle Removal aruet enan er eren arit een aeree utu aee tori odes dal 29 x EL e 30 35 Glossary OF NI M M 36 37 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 cus tomers and the industry as a world class sup plier and the quality leader in everything we do This Service and Repair Manual is designed to provide information us
5. 21 Install the side housing See page 19 22 Install the seals in the side housing See page 18 23 Fill the transaxle with new oil See page 10 24 Install the control arm and friction pack See page 17 25 Install the brake assembly and bypass arm See page 16 Figure 18 310 0510 IHT 25 HYDRAULIC COMPONENTS A ET ET Axle Horn Figure 19 Figure 22 Figure 20 Figure 23 Short Shaft Figure 24 Swashplate Pump Block Assembly Figure 21 310 0510 IHT 26 TRANSAXLE INSTALLATION Use the following procedure to complete the installation of the transaxle on the vehicle 1 Install and secure the transaxle on the vehicle according to the instructions in the vehicle owner s manual 2 With the vehicle raised install the wheels on the axles and snug the wheel hardware 3 Lower the vehicle wheels to the ground and torque the wheel hardware per the vehicle owner s manual 310 0510 IHT ASSEMBLY AFTER A COMPLETE TEARDOWN If the unit has been torn down completely the following summary identifies the assembly pro cedures necessary to completely assemble the unit Each assembly procedure is located by a page reference The part reference numbers provided in each assembly procedure are keyed to the individual exploded views and are also keyed to the complete unit exploded view on page 32 1 Install the hydraulic compon
6. 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 310 0510 IHT 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 m
7. 19 from the swashplate 4 Center Section Filter 14 15 16 17 18 19 See Fig 19 Remove the center section mounting screws 44 NOTE The center section is under motor block piston spring pressure These screws are factory in stalled to 700 lbs 80 Nm and use anaerobic thread adhesive A breaker bar will be required at this step Clean the inter nal threads of the mounting holes with compressed air Remove the center section and filter as sembly 124 Fig 20 See Fig 21 Remove the filter 45 from the filler base 46 by snipping the four posts with side cutters or applicable tool NOTE This filter cannot be reused Remove and inspect the deflector 107 bypass actuator 47 and bypass spring 43 Note the location of both check plugs 23 amp 75 before removal for correct placement during reassembly Remove and inspect the check plug assemblies 23 for debris or damage Remove the filter base 46 and discard it NOTE The filter base is included in the fil ter kit to be installed during reassembly of the unit Motor Block 20 21 See Fig 22 Remove the motor cylinder block assembly 5 from the housing 1 Disassemble the motor cylinder block as sembly 5 Check each piston for proper operation by pressing the pistons in and releasing them in the block bore Disas semble the motor cylinder block Check for piston block wear in the cylinder bore I
8. RETURN TO NEUTRAL SETTING FOOT CONTROL A WARNING POTENTIAL FOR SERIOUS INJURY Certain procedures require the vehicle engine to be operated and the vehicle to be raised off the ground To prevent possible injury to the servicing techni cian and or bystanders insure the vehicle is properly secured The return to neutral mechanism on the trans mission is designed to set the directional con trol into a neutral position when the operator removes their foot from the foot control Follow the procedures below to properly adjust the return to neutral mechanism on the transaxle 1 Confirm the transaxle is in the operat ing mode bypass disengaged Raise the vehicle s drive tires off the ground to allow free rotation NOTE It may be necessary to remove the drive tire from the axle hub to access the linkage control and the transaxle return arm 2 Remove the Original Equipment Manufac turer s OEM s control linkage at the control arm Refer to Figure 5 3 Start the engine and increase the throttle to full engine speed ROTATION A A WARNING Do not attempt any adjustments with the engine running Use extreme caution while inspecting all vehicle linkage Follow all safety procedures outlined in the vehicle owner s manual 4 Check for axl
9. See page 20 6 Remove the flat washer 52 motor shaft and pinnion gear 24 amp 27 and the flat washer 108 7 Remove the bypass rod 48 Clean the magnet 42 of any foreign material INSPECTION 1 Inspect the motor shaft 24 pinnion gear 27 and flat washers 52 amp 108 for wear or damage MOTOR SHAFT AND BYPASS ROD 2 Inspect the bypass rod 48 for wear or damage ASSEMBLY 1 Insert the bypass rod s 48 short end into the housing while aligning the rod s flat with the bypass actuator Confirm proper bypass function 2 Insert the motor shaft 24 with the pinnion gear 27 and flat washers 52 amp 108 into the center section 3 3 Install the axle shaft differential and reduc tion gears Refer to page 20 4 Install the side housing Refer to page 19 5 Install new seals Refer to page 18 6 Fill the transaxle with oil See page 10 7 Install the control arm and friction pack See page 17 8 Install the brake assembly and bypass arm See page 16 Figure 13 Motor Shaft amp Bypass Rod Assemblies 310 0510 IHT 21 INPUT SHAFT Refer to Figure 14 DISASSEMBLY 1 Remove the brake assembly and bypass arm See page 16 Remove the control arm and friction pack See page 17 Drain the oil from the transaxle See page 10 Remove the side housing See page 19 Remove the seals in the side housing See page 18 Remove the axle shaft differential and re duction gea
10. a new retaining ring 74 Bypass Seal 1i Remove the bypass arm and any attach ments to the bypass arm See page 16 The seal 51 can be replaced by following steps 3 6 of the procedure used to replace the axle seals Figure 10 Seal Kit Replacement 310 0510 IHT Refer to Figure 11 DISASSEMBLY 1 Remove the brake assembly and bypass arm See page 16 Remove the control arm and friction pack See page 17 Remove the oil from the transaxle See page 10 After all of the oil has been removed from the transaxle remove the housing screws 7 and torque strap screw 8 Pull away the side housing 2 leaving the axle assembly 35 Page 32 in the main housing 1 It may be necessary to use screwdrivers at the pry points to break loose the sealant positions B H and G J Fig 11 Remove all the seals in the side housing See page 18 Clean off all the old sealant on the side and main housings Take care not to damage the sealing surfaces A wire brush and sol vent is effective INSPECTION 1 Inspect the bearing areas in the side hous ing SIDE HOUSING ASSEMBLY 1 Apply a bead of sealant around the perime ter of the side housing face See sealant pattern on page 28 Install the axle and sleeve bearing 31 Note the orientation of the locating tab on the sleeve bearing It is essential for this to align with the side housing bore In
11. accomplish the required repairs Each disassembly procedure is followed by a corresponding assembly procedure Reassembly is accomplished by performing the Assembly portions of the procedures If the unit has been completely disassembled a sum mary of the assembly procedures in the order in which they should occur is given on page 27 310 0510 IHT TOOLS AND TORQUES Miscellaneous 310 0510 Service amp Repair Manual Flat Blade Screw Driver 2 Torque Wrench Air Impact Wrench Rubber Mallet Breaker Bar Side Cutters Snips Pliers Needle Nose Large External Snap Ring Operation Side Housing Screws Housing Stud Control Arm Screw Check Plugs Center Section Bolts Brake Yoke Bolt Brake Yoke Bolt Friction Pack Mounting Stud Friction Pack Nut Expansion Tank Hose Fitting Belt Keeper Screw Bracket Support Bolt Friction Pack Wedge Screw Puck Inner Wedge Bolt Adjusting Puck Screw RTN Screw Bracket Screw Fan Pulley Input Shaft Nut Fan Pulley Screws Fan Pulley Nuts Cruise Damper Bracket Nuts Axle Hub Nut 310 0510 IHT Table 4 Required Tools Sockets 1 2 3 8 Adapter 1 2 Deep 7 16 Deep 9 16 Deep 3 4 Deep 718 10 mm T 25 Torx Head Table 5 Required Torque Values U S Torque 105 155 Ib in 230 310 Ib in 230 310 Ib in 280 400 Ib in 525 700 Ib in 80 120 Ib in 80 120 Ib in 50 120 Ib in 85 120 Ib in 96 120 Ib in 40 70 Ib in 42 65 Ib in 30 70 in Ib 42 65 Ib in 250 320 Ib i
12. valve Case Drain Line Return Line A line returning fluid from the component housing to the reservoir Cavitation A concentrated gaseous condition within the fluid causing the rapid implosion of a gaseous bubble Center Section A device which acts as the valve body and manifold of the transmission Charge Pump A device which supplies replenishing fluid to the fluid power system closed loop Charge Pressure The pressure at which replenishing fluid is forced into a fluid power system Charge Relief Valve A pressure control valve whose primary function is to limit pressure in the charge circuit Check Valve A valve whose primary function is to restrict flow in one direction Closed Loop A sealed and uninterrupted circulating path for fluid flow from the pump to the motor and back Decay Rate The ratio of pressure decay over time End Cap See Center Section Entrained Air A mechanical mixture of air bubbles having a tendency to separate from the liquid phase Gerotor A positive displacement pump frequently used as a charge pump Hydraulic Motor A device which converts hydraulic fluid power into mechanical force and motion by transfer of flow under pressure Hydraulic Pump A device which converts mechanical force and motion into hydraulic fluid power by producing flow Hydrostatic Pump See Hydraulic Pump 36 310 0510 IHT GLOSSARY OF TERMS Hydrostatic Transaxle A multi component assembly including a g
13. IT REPLACEMENT Before disassembly wipe the unit free of any debris to avoid contamination Refer to Figure 10 Axle Seal 1 2 3 T 8 9 Remove the axle clips 93 from the axle horns for units with keyed axle shafts Remove the seal retaining rings 12 Carefully pull the axle seals 34 out of the housing bore with a hook type tool Care must be taken to avoid damage to the hous ing bore or to the shaft sealing areas Lubricate the new seal with petroleum jelly prior to installation Wrap the shaft keyway splines with cello phane to prevent damage to the seal lip dur ing installation Slide the seal over the shaft and press it into the housing bore The seal should seat against the sleeve bearing Install the seal retaining rings 12 Install the axle clips 93 if applicable Input Seal 1 Remove the input pulley and fan from the input shaft The seal 13 can be replaced by following steps 2 6 of the procedure used to replace the axle seals Trunnion Seal 1 Remove the control arm and attach ments to the control arm See page 17 The seal 17 can be replaced by following steps 3 6 of the procedure used to replace the axle seals Brake Seal 1 Remove the brake assembly and at tachments to the brake assembly See page 16 The seal 74 can be replaced by following steps 3 6 of the procedure used to replace the axle seals Install
14. Id SQNVMOL 38 ISM 39VH MOIHL 2 5 ZL 55 ER 95 NN 310 0510 IHT 30 310 0710 ITEMS LIST DESCRIPTION Main Housing Assembly Black Compression Spring Brake Anti Drag Main Housing Black Washer Flat 51 x 1 00 x 03 Bushing 865 x 985 x 790 Washer Flat 34 x 88 x 06 Side Housing Assembly Black Oil Seal 625 X 1 0 X 25 Side Housing Black Check Plug Assy 027 Washer B Port Bushing 865 x 985 x 790 Ball Bearing 62 1 0 x 1 38 x A4 Bushing 624 x 719 x 562 Socket Head Cap Screw 5 16 24 x 1 1 2 Center Section Assembly Spacer Locating Center Section Machined Screw Countersunk 5 16 18 x 1 0 Bushing 707 x 788 x 591 Arm Return Swashplate Trunnion Machined Puck Adjusting Block Assembly Washer 32 x 1 60 x 24 Block Cylinder Spring Extension Piston Spacer 260 x 560 x 87 Spring Compression Bracket Torque Thrust Washer Deflector Sealant Washer Motor Shaft 71 x 1 16 x 04 Hex Flange Screw 1 4 20 x 1 25 Plug 9 16 18 Metal Shaft Input Torx Head Screw 5 16 18 x 1 5 Ring Retaining Spring Guide Washer Flat 1 23 x 1 57 x 04 Pin Spring 304 x 75 Ring Retaining Fan 7 0 in 10 Blade Seal Lip 17 x 40x 7 Pulley 3 86 in Ball Bearing 17MM x 40MM x 12MM Nut Hex Lock 1 2 20 w nylon insert Hex Flange Head Screw 5 16 24 x 0 94 w patch Washer OD slotted 53 x 1 63 x 06 Lip Seal 18 X 32X 7 Center Section Filter Bypass Assy Arm Control Center Sectio
15. a primary means of assuring satisfactory life on repaired units Thoroughly clean all exposed surfaces prior to any type of maintenance Cleaning of all parts by using a solvent wash and air drying is usually adequate As with any precision equipment all parts must be kept free of foreign material and chemicals Protect all exposed sealing surfaces and open cavities from damage and foreign material The external surfaces should be cleaned before beginning any repairs Upon removal it is recommended that all seals O rings and gaskets be replaced During installation lightly lubricate all seals O rings gaskets with a clean petroleum jelly prior to assembly Also protect the inner diameter of seals by covering the shaft with a cellophane plastic wrap etc material Parts requiring replacement must be replaced from the appropriate kits identified in the Items Listing found at the end of this manual Use only original Hydro Gear replacement parts found listed in BLN 51427 CD IMPORTANT When internal repair is per formed on the 310 0510 IHT the filter assem bly must be replaced TRANSAXLE REMOVAL It is necessary to remove the 310 0510 from the vehicle before performing the repair procedures presented in this section LIMITED DISASSEMBLY The following procedures are presented in the order in which they must be performed to completely disassemble the unit Do not disassemble the unit any farther than is necessary to
16. al 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 prob lems Table 2 310 0510 Troubleshooting Checklist Possible Cause Corrective Action UNIT OPERATES IN ONE DIRECTION ONLY Control linkage bent or out of adjustment Drive belt slipping or pulley damaged Repair or replace linkage Page 9 Repair or replace drive belt or pulley Page 9 VEHICLE DOES NOT DRIVE TRACK STRAIGHT Vehicle tires improperly inflated Control linkage bent loose or out of adjustment Bypass partially engaged Refer to vehicle manufacturer suggested pressure Repair adjust or replace vehicle linkage Adjust bypass linkage UNIT IS NOISY Oil level low or contaminated oil Excessive loading Brake setting incorrect Loose parts Bypass assembly sticking Air trapped in hydraulic system Fill to proper level or change oil Page 10 Reduce vehicle loading Page 9 Adjust brake to proper setting Page 13 Repair or replace loose parts Repair or replace valve or linkage Purge hydraulic system Page 11 UNIT HAS NO LOW POWER 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 Adjust to correct setting Repair or
17. ating Pin Bolt Hex Head 1 4 20 x 2 w patch Spacer Spring Brake Arm Bias Arm Brake Nut Castle 5 16 24 Cotter Pin 3 32 X 3 4 310 0510 IHT 31 310 0610 EXPLODED VIEW 121 THICK RACE MUST BE TOWARDS PISTONS ITEMS NOT SHOWN SEALANT 6 57 20W50 OIL 76 3 OZ 127 KIT 75 PORT SEAL amp O RING THICK RACE MUST BE TOWARDS PISTONS 32 63 71 310 0510 IHT 310 0610 ITEMS LIST DESCRIPTION No DESCRIPTION Main Housing Assembly Spacer 26 57 x 87 Main Housing Spring Brake Arm Bias Bushing 865 x 985 x 790 Arm Brake Pin Headless Standard Nut Castle 5 16 24 Side Housing Assembly Cotter Pin 3 32 X 3 4 Side Housing Compression Spring Brake Anti Drag Bushing 865 x 985 x 790 Washer Flat 51 x 1 00 03 Bushing 624 x 719 x 562 Washer Flat 34 x 88 x 06 Center Section Assembly Kit Motor Shaft Seal 625 X 1 0 X 25 Center Section Machined 5 piston Check Plug Assy 027 Washer B Port Bushing 707 x 788 x 591 Stud 5 16 24 Friction Pack Swashplate Trunnion Machined Puck 330 x 1 50 x 0975 Block Assembly Spring Helical Compression Block Cylinder Spacer 32 x 59 x 50 Piston Nut Hex lock 5 16 24 w nylon insert Spring Compression Wedge Friction Pack Thrust Washer Spacer Friction Pack Sealant Fitting 5 16 SAE 5 32 Tube Screw Hex Washer 1 4 20 x 1 25 Hose Expa
18. ay 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 FLUID CHANGE FLUID CHANGE PROCEDURE This transaxle is factory filled sealed and does not require oil maintenance However in the event of oil contamination or degradation oil addition or change may alleviate certain per formance problems 1 Remove the transaxle from the vehicle 2 Clean the expansion tank and oil fill port areas of any debris 3 Remove the oil fill port fitting 4 Position the transaxle so the oil will drain completely out of the housing 5 After all the oil is drained from the transaxle remove the expansion tank by removing the self tapping bolt 10 32 x that holds the tank support bracket 6 Remove the tank and drain the oil from the tank DO NOT remove the vent cap from the tank DO NOT remove the tank hose or o ring unless a replacement is needed 7 Install the tank by first inserting the hose into the opening in the expansion tank Push the tank opening over the o ring to en sure a proper seal 8 Install the tank support bracket and self tap ping bolt making sure not to cross thread the bolt Torque the bolt to the lower value of the torque specification l
19. cedures should be imple mented any time a hydrostatic system has been opened to facilitate maintenance or any additional oil has been added to the system Air creates inefficiency because its compres sion and expansion rate is higher than that of the oil approved for use in hydrostatic drive systems The resulting symptoms in hydrostatic systems may be 1 Noisy operation 2 Lack of power or drive after short term operation 3 High operation temperature and excessive expansion of oil Before starting make sure the transaxle transmission is at the proper oil level If it is not fill to the specifications outlined on page 10 Figure 4 310 0510 IHT PURGING PROCEDURES The following procedures should be performed with the vehicle drive wheels off the ground then repeated under normal operating condi tions 1 With the bypass valve open and the engine running slowly move the directional control in both forward and reverse directions 5 to 6 times as air is purged from the unit the oil level will drop 2 With the bypass valve closed and the engine running slowly move the directional control in both forward and reverse directions 5 to 6 times Check the oil level and add oil as required after stopping engine 3 It be necessary to repeat Steps 1 and 2 until all the air is completely purged from the system When the transaxle moves forward and reverse at normal speed purging is complete 11
20. e rotation If the axles do not rotate go to Step 5 If the axles rotate go to Step 6 5 Stop the vehicle s engine Reattach and ad just the OEM linkage according to the OEM manual Recheck according to Step 3 and 4 Stop the vehicle engine Refer to Figure 5 6 Note the axle directional movement Stop the vehicle engine Loosen the adjusting puck screw until the puck can be rotated Rotate the adjusting puck the opposite di rection of the wheel rotation in 5 degree in crements Tighten the adjusting puck screw Refer to Table 5 Required Torque Values Page 15 Recheck according to steps 3 and 4 Stop the vehicle engine Reattach and adjust the OEM linkage according to the OEM manual Recheck according to steps 3 and 4 Refer to Figure 5 446 Control Arm Brake Arm Bypass Arm Adjusting Puck Figure 5 Return to Neutral Foot Control 310 0510 IHT 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 finger tightening or loosening the castle nut 3 Install a new cotter pin to secure the castle nut and then install the brake arm bias spring BRAKE ARM BIAS SPRING TOP BRAKE PUCK Figure 6 Brake Compo
21. ear case and a hydrostatic transmission Hydrostatic Transmission The combination of a hydraulic pump and motor in one housing to form a device for the control and transference of power Inlet Line A supply line to the pump Integrated Hydrostatic Transaxle IHT The combination of a hydrostatic transmission and gear case in one housing to form a complete transaxle Manifold A conductor which provides multiple connection ports Neutral Typically described as a condition in which fluid flow and system pressure is below that which is required to turn the output shaft of the motor Pressure Decay falling pressure Priming The filling of the charge circuit and closed loop of the fluid power system during start up frequently achieved by pressurizing the fluid in the inlet line Purging The act of replacing air with fluid in a fluid power system by forcing fluid into all of the components and allowing the air a path of escape Rated Flow The maximum flow that the power supply system is capable of maintaining at a spe cific operating pressure Scoring Scratches in the direction of motion of mechanical parts caused by abrasive contami nants Swash Plate A mechanical device used to control the displacement of the pump pistons in a fluid power system System Charge Check Valve A valve controlling the replenishing flow of fluid from a charge cir cuit to the closed loop in a fluid power system System Pressure The press
22. eful in servicing and troubleshooting the Hydro Gear 310 0510 Integrated Hydrostatic Transaxle IHT Trou bleshooting for the 310 0510 is further illus trated in video BLN 51368 NTSC Also included is a glossary of terms that are frequently used throughout the industry and in Hydro Gear service publications Understand ing 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 310 0510 IHT FOREWORD 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 OPEESA Outdoor Power Equip ment and Engine Service Association at 860 767 1770 or their Hydro Gear Distributor Many distributors will be hosting certification testing These study guides will cover most of the prod ucts 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 SECTION 1 DESCRIPTION AND OPERATION INTRODUCTION The purpose of this manual is to provide information useful in servicing the Hyd
23. ents See pages 23 26 2 Install the input shaft See page 22 3 Install the bypass rod See page 21 4 Install the axle shaft differential and reduc tion gears See page 20 5 Install the side housing See page 19 6 Install new seals in the side housing Refer to page 18 7 Fill the transaxle with new oil See page 10 8 Install the control arm and friction pack See page 17 9 Install the brake assembly and bypass arm See page 16 10 Install the transaxle onto the vehicle 11 Perform the purge procedures listed on page 11 12 Perform the return to neutral procedure on page 12 27 SEALANT APPLICATION NOTE Prior to applying the new sealant the old sealant must be removed from all surfaces A small consistent bead of the sealant around the housing face will be sufficient Use sparingly The illustration below indicates the correct areas Sealant Path 28 310 0510 IHT 310 0710 INTEGRATED HYDROSTATIC TRANSAXLE DESCRIPTION The 310 0710 transaxle is an upgraded 310 0510 unit with different axle shafts pump cylinder block assembly center section and seal kit The 310 0710 will have as standard black axle shafts Flanged hubs will be an TRANSAXLE REMOVAL It is necessary to remove the 310 0710 from the vehicle before performing the repair proce dures presented in the repair section Use the following procedure to prepare the unit for re moval from the vehicle available opti
24. erly 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 ex tension 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 capabil ity 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 sol vents in an area where a source of ignition may be present Discard used cleaning material in the appropri ate containers SECTION 3 TROUBLESHOOTING A WARNING Do not attempt any servicing or adjust ments with the engine running Use extreme caution while inspecting the drive belt assembly and all vehicle link age 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 operation
25. haft Axle 75 x 11 39 DD R H Actuator Bypass Shaft Axle 75 x 17 99 DD L H Deflector Miter Gear 12T Splined Base Filter w poppet Miter Gear 12T 0 5 ID Kit Seal amp O Ring Pin Seal Lip 17 x 40x 7 Ring Spiral Retaining Seal Lip 18x 32x 7 Pin Jackshaft Seal Lip 75 x 1 577 x 250 Magnet Ring Seal Lip 250 x 750 x 250 TC Spring Bypass Seal Lip 625 x 1 0 x 25 Bolt Hex Flange 3 8 24 x 2 5 O Ring 299 x 505 x 103 Filter Kit Expansion Tank Base Filter Tank Expansion Assembly Actuator Bypass Cap Expansion Rod Bypass Actuator Bolt Self Tapping 10 32 x 1 2 Arm Bypass Bracket Expansion Tank Retaining Ring 250 External Kit 60T Bull Gear Diff Pins Seal Lip 250 x 750 x 250TC Gear 60T Flat Washer 5 8 x 1 0 x 05 Pin 0 5 OD Retaining Ring Spring Helical Compression Washer Thrust 59 x 79 x 04 20W 50 Oil Brake Yoke Rotor Brake Brake Puck Puck Plate Brake Actuating Pin Bolt Hex Hd 1 4 20 x 2 w patch Spacer Spring Brake Arm Bias Arm Brake 310 0510 IHT 35 GLOSSARY OF TERMS Axial Piston Type of design for hydraulic motors and pumps in which the pistons are arranged parallel with the spindle input or output shaft Bantam Duty A descriptive term relating to the product capacity meaning light duty Bypass Valve A valve whose primary function is to open a path for the fluid to bypass the motor or pump Also referred to occasionally as the freewheel valve or dump
26. hat 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 310 0510 IHT 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 fication of SL is recommended A 20W 50 en gine oil has been selected for use by the fac tory and is recommended for normal operating temperatures FLUID VOLUME AND LEVEL Fluid volume information is provided in Table 3 Certain situations m
27. isted in Table 5 9 Fill the transaxle at the oil fill port according to Figure 4 10 Install the oil fill port fitting EXPANSION TANK FUNCTION The expansion tank allows the 310 0510 to operate free of air entrainment and provides maximum lubrication to the mechanical and hydraulic components in the transaxle As the 310 0510 transaxle is operated oil in the transaxle housing heats up which causes the oil to expand The oil flows through an internal hose to the bottom of the vented expansion tank As the oil cools the oil in the transaxle housing contracts causing the oil level to go down in the housing This creates a negative pressure in the housing causing the oil to be drawn back into the case This keeps the transaxle housing full of oil at specified operating temperatures Table 3 Fluid Volumes for the 310 0510 IHT 20W 50 engine oil 79 fl oz 2336 ml PORT TE BE T 1 31 75mm Max Depth at 50 100 F 10 38 C 10 Figure 4 310 0510 Fluid Level Fill Port JR JH 310 0510 IHT Due to the effects air has on efficiency in hydrostatic drive applications it is critical that it be purged from the system These purge pro
28. k plate 61 and puck 60 Remove the bypass arm retaining ring 50 and bypass arm 49 Discard the retaining ring Remove the brake rotor 59 and puck 60 Note The hub on the rotor faces away from the transaxle INSPECTION 1 Inspect the brake arm bias spring 66 castle nut 69 washer 73 brake arm 68 actuating pins 62 spring 71 brake yoke screws 63 64 brake yoke 58 pucks 60 puck plate 61 bypass arm 49 spacer 65 and brake rotor 59 for wear or dam age ASSEMBLY 1 Install the brake puck 60 brake rotor 59 Install the bypass arm 49 onto the bypass rod Secure the bypass arm with a new re taining ring 50 Install the brake puck 60 puck plate 61 brake yoke assembly 58 spacer s 65 and brake yoke screws 63 64 Insert the brake actuating pins 62 into the brake yoke 58 Install the spring 71 Assemble the brake arm 68 washer 73 and castle nut 69 Adjust the brake gap Refer to page 13 Install the brake arm bias spring 66 Figure 8 Brake Assembly and Bypass Arm 310 0510 IHT CONTROL ARM AND FRICTION PACK Refer to Figure 9 DISASSEMBLY 1 2 Remove the brake assembly See page 16 Loosen and remove the friction pack lock nut 80 flat washer 73 spring 78 spacer 79 washer clip 82 and puck 77 Discard the lock nut 80 Remove the hex head screw 16 from the directional control
29. n spect the pistons piston springs and piston 23 HYDRAULIC COMPONENTS 22 23 seats for excessive wear or damage NOTE Piston seats may be held in place in the piston by residual oil Reassemble the pistons springs and seats into the cylinder block and set aside Remove the thrust bearing assembly 19 from the housing 1 Inspect the thrust bearing and thrust bearing cavity in the housing INSPECTION 1 Inspect the pump cylinder block running surface for wear or damage Inspect the swashplate and thrust bearing assemblies for wear or damage Inspect the center section block running surfaces NOTE These sealing surfaces should be smooth in appearance without scratches scoring nicks or abrasions Drag a fingernail across the surface to detect un even wear or scratches which may not be visible Inspect the threaded check plug ports of the center section for debris or damage Inspect the motor cylinder block running surface for damage and wear Inspect all bearing bushing and wear areas in the housing ASSEMBLY Motor Block 1 24 See Fig 22 Turn the housing 1 so the axle horn is pointing down This will assist in the installation of the thrust bearing assem bly 19 keeping it in the bearing cavity dur ing installation of the center section assem bly Insert the thrust bearing 19 in the housing 1 NOTE Place the thin race of the bear ing towards the housing bearing ca
30. n 180 240 Ib in 230 310 Ib in 300 460 Ib in 65 90 Ib in 35 50 Ib in 160 210 Ib in 180 200 Ib ft Metric Torque 12 17 Nm 26 35 Nm 26 35 Nm 32 45 Nm 60 80 Nm 9 14 Nm 9 14 Nm 6 14 Nm 10 14 Nm 11 14 Nm 5 8 Nm 5 7 Nm 3 4 8 Nm 5 7 Nm 28 36 Nm 20 27 Nm 26 35 Nm 34 52 Nm 8 10 Nm 4 6 Nm 18 24 Nm 244 271 Nm Description Screw 14 20 x 1 25 Stud 5 16 24 Hex Screw 5 16 24 x 0 75 Check Plug Assembly Screw 3 8 24 x 2 5 HFHCS 4 20 x 2 Bolt 74 20 x 1 Stud 5 16 24 Lock Nut 5 16 24 Fitting 5 16 SAE 5 32 Tube Screw Self Tapping 10 32 x 5 Bolt 10 32 x 0 5 Screw Self Tapping 10 32 x 5 Bolt 10 32 x 0 5 Socket Hd CS 5 16 24 x 1 50 Screw Countersunk 5 16 18 x 1 Screw Torx Hd 5 16 18 x 1 50 Nut Hex Lock 72 20 w nylon Screw Hex Flange 54 20 x 75 Nut Hex 4 20 Nut Hex 5 16 18 Nut Hex Lock 3 4 16 15 BRAKE ASSEMBLY AND BYPASS ARM Refer to Figure 8 DISASSEMBLY 1 Remove the brake arm bias spring 66 Note the orientation of the spring for proper reassembly Remove the cotter pin 70 castle nut 69 washer 73 brake arm 68 spring 71 and actuating pins 62 Note the orientation of the brake arm for proper reassembly Dis card the cotter pin 70 Remove the two brake yoke screws 63 64 and spacer 65 from the side housing as sembly 2 Note the orientation of the spacer s 65 on the brake yoke assembly to ensure proper reassembly Remove the brake yoke assembly 58 puc
31. n Machined Bearing 30X52X13 Thrust Base Filter Check Plug Assembly 027 Washer A Port Check Plug Assy Shaft Motor Spring Bypass Gear Pinion 13T Actuator Bypass 10T 48T Gear Deflector Gear 10T Jackshaft Filter 60T Bull Gear Bushing 707 X 788 X 591 Sleeve Bushing Inboard Filter Assembly Sleeve Bushing Outboard 1 002 x 1 571 x 625 Kit Fan Pulley Washer Flat 77 x 1 5 x 10 Kit Seal amp O Ring Lip Seal Axle Seal Seal Lip 17 x 40x 7 Shaft Black Axle 1 00 75 x 10 65 Flange R H Seal Lip 18 x 32x 7 Shaft Black Axle 1 00 75 x 16 25 Flange R H Seal Lip 1 00 X 1 577 X 250 Miter Gear 12T Splined Seal Lip 250 X 750 X 250 Miter Gear 12T 0 5 ID Seal Lip 625 X 1 0 X 25 Shaft O Ring 299 x 505 x 103 Ring Spiral Retaining Assembly Block 7 Piston Pin Jackshaft Block Cylinder Magnet Ring Piston Spring Bypass Spring Compression Bolt Hex Flange 3 8 24 x 2 5 Seat Filter Nut Hex Lock 3 4 16 Base Filter Assembly Hub Actuator Bypass Hub 4 Stud Metric Painted Rod Bypass Actuator Stud M12 x 1 5 Rib Neck Arm Bypass Plug 9 16 18 Magnetic Retaining Ring 250 External Fitting 90 9 16 SAE Beaded Seal Lip 250 x 750 x 250 TC Kit 60T Bull Gear Diff Pins Flat Washer 63 x 1 0 x 05 Gear 60T Retaining Ring Pin 0 5 OD Spring Block Bulletin Bull Gear Washer Thrust 59 x 79 x 04 20W 50 Oil Brake Yoke Kit Disk Brake Brake Puck Puck Plate Brake Actu
32. n per sonal 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 all inclusive 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 person nel to service or repair the equipment 310 0510 IHT 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 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 ord
33. nents 310 0510 IHT FRICTION PACK ADJUSTMENT The friction pack dampens or holds the opera tor control lever in its desired position Adjustment for the amount of drag or holding force can be made by turning the friction pack nut in or out Adjustments should be made in no more than 1 4 turn increments Over tightening will result in difficulty or inability of the operator to move the control lever Note The factory setting for the friction pack is tightening of the friction pack nut to 100 in lbs 11 Nm torque The friction pack nut is then backed off per the vehicle manufacturer s specifications FRICTION PACK NUT CONTROL ARM Figure 7 Friction Pack 13 SECTION 5 REPAIR HOW TO USE THIS SECTION Each subassembly illustrated in this section is illustrated by an exploded view showing the parts involved The item reference numbers in each illustration are for assembly instructions only See pages 31 and 33 for part names and descriptions A complete ex ploded view and item list of the transaxle is pro vided at the end of this section Many of the parts and subassemblies of this transaxle can be removed and serviced inde pendently of other components Where some components and assemblies must be removed before a given assembly can be serviced that information is given at the beginning of the disassembly instructions GENERAL INSTRUCTIONS Cleanliness is
34. nsion Tank Center Section Machined 5 piston Cap Vent Bushing 707 x 788 x 591 Bolt Self Tapping 10 32 x 1 2 Swashplate Trunnion Machined Bearing Ball 62 x 1 38 x 44 Block Assembly Screw Socket Hd Cap 5 16 24 x 1 5 Block Cylinder Spacer Locating Pistons Screw Countersunk 5 16 18 1 0 Springs Compression Arm Return Thrust Washer Puck Adjusting Sealant 10 1 oz Washer Flat 32 x 1 60 x 24 Hex Flange Screw 1 4 20 x 1 25 Spring Extension Double Loop Stud 5 16 24 Hex Double End Spacer 26 x 56 x 87 Shaft Input Bracket Torque Ring Retaining Deflector Washer Flat 1 23 x 1 57 x 04 Washer Flat 71 x 1 16 x 04 Ring Retaining Plug 9 16 18 Metal Seal Lip 17 x 40x 7 Screw Torx Hd 5 16 18 x 1 5 Ball Bearing 17MM x 40MM x 12MM O Ring 299 x 505 x 103 Hex Flange Head Screw 5 16 24 x 0 94 w patch Bracket Support Expansion Tank Lip Seal 18x 32x 7 Spring Guide Arm Control Center Section Filter Bypass Assy Bearing 30 x 52 x 13 Thrust Center Section 5 piston Check Plug Assembly 027 Bleed Washer A port Base Filter w poppet Shaft Motor Check Plug Assy 027 Bleed Washer Gear Pinion 13T Spring Bypass 50 in 10T 48T Gear Actuator Bypass Gear 10T Jackshaft Deflector 60T Bull Gear Bottom Filter Sleeve Bushing Inboard Bushing 707 x 788 x 591 Sleeve Bushing 75 x 1 575 x 625 Filter Assembly Washer 77 x 1 1 2 x 10 THK Bottom Filter Lip Seal Axle Seal Spring Bypass 50 in S
35. nsion Tank 7 56 Stud 5 16 18 THD 5 16 18 Strap Cap Barbed Vent Shaft Input Bolt Self Tapping Ring Retaining Puck Inner Wedge Washer Flat 1 23 x 1 57 x 04 Spring Clip Housing Thrust 75 In Axle Ring Retaining Deflector Seal Lip 17 x 40 x 7 Washer Motor Shaft 71 x 1 16 x 04 Ball Bearing 17MM x 40MM x 12MM Plug 9 16 18 Metal Bolt Hex Flange 5 16 24 x 0 94 w patch O Ring 299 x 505 x 103 Lip Seal 18 x 32x 7 Bracket Expansion Tank Arm Control Kit Fan 7 0 in 10 Blade Bearing Thrust 30 x 52 x 13 Pulley 3 86 in Shock Valve Assembly 027 Washer A Port Nut Hex Lock 1 2 20 w nylon insert Shaft Motor Washer OD slotted 53 x 1 63 x 06 Gear Pinion 13T Bracket Belt Keeper Angled 10T 48T Gear Center Section Filter Bypass Assy Gear 10T Jackshaft Center Section Machined 60T Bull Gear Base Filter Sleeve Bushing Inboard Shock Valve Assy Sleeve Bushing 752 x 1 571 x 625 Check Plug Assy Washer Flat 77 x 1 5 x 10 Spring Bypass Lip Seal 750 x 1 577 x 250 Actuator Bypass Shaft Axle 75 x 11 39 Key R H Deflector Shaft Axle 75 x 16 99 Key L H Filter Miter Gear 12T Splined Bushing 707 X 788 X 591 Miter Gear 12T 0 5 ID Filter Assembly Shaft Kit Fan Pulley Ring Spiral Retaining Kit Seal amp O Ring Pin Jackshaft 50 x 2 43 Seal Lip 17 x 40 x 7 Magnet Ring Seal Lip 18 x 32x 7 Spring Bypass Seal Lip 1 00 X 1 577 X 250 Bolt Hex Flange 3 8 24 x 2 5 Seal Li
36. oil from the transaxle See page 10 Remove the side housing See page 19 Remove the seals in the side housing See page 18 Remove the axle shaft differential and re duction gears Refer to page 20 Remove the motor shaft and bypass rod See page 21 Remove the input shaft See page 22 See Fig 15 Remove the swashplate 4 and pump cylinder block 5 as assem bly NOTE Removal will be aided by apply ing a small amount of pressure on the trun nion mounted swashplate towards the cen ter section Also note that the control arm 18 Page 32 may be loosely assembled at this point to assist in swashplate removal While gently removing the swashplate and block assembly keep the block face flush with the center section to minimize damage to the running surface 10 See Fig 16 Disassemble the pump oylin 11 der block 5 from the swashplate 4 See Fig 17 Check each piston for proper operation by pressing the pistons in and releasing them in the block bore Disas semble the pump cylinder block Check for piston block wear in the cylinder bore In spect the pistons 1 piston springs 2 and piston seats 3 for excessive wear or dam age NOTE Piston seats may be held in place in the piston by residual oil 310 0510 IHT 12 13 HYDRAULIC COMPONENTS Reassemble the pistons springs and seats into the cylinder block and set aside See Fig 18 Remove the thrust bearing assembly
37. on 1 With the vehicle wheels on the ground loosen the nuts retaining the hubs on the transaxle Use an air impact wrench and socket to loosen the nuts Except for flanged hub removal and assembly described below repair techniques for this model are the same as described in the preceding sections of this manual Table 6 illustrates key feature differences between the 310 0510 and the 310 0710 2 Lift the vehicle wheels from the ground and remove the nut completely 3 Remove the wheel from the hub 4 Using a wheel or gear puller remove the hub from the shaft Always inspect the hub for damage after removal FEATURE COMPARISIONS Table 6 Transaxle Features Note that larger 1 axle shafts make it necessary to specify a seal kit and axle bushings different from the 310 0510 unit The center section pump cylinder block assembly and associated kits also differ from those on the 310 0510 Refer to the appropriate model schematic for specific component part numbers 310 0510 IHT 29 310 0710 EXPLODED VIEW 2 4 uy seh Bol 40 17 8v 2 3 ONIN O TWAS LIM 171 YE iz ZO 2 79 110 OSMOZ LS N 1 1 35 9 1804 22T N NMOHS LON 573 1 1304 9 SL EI 97 wy SNOLSId A S SQuVMOL 38 KOY ISMN 30VY MOIHL S Ore x ns 791 24 CS 6l 6 Ov LS e se lt P di N 6c LE 04 9 Ir os 0 21 8c 22 2 5 346 601 SNOLS
38. ositive 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 310 0510 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 zo docomz Figure 1 310 0510 Hydraulic Schematic 310 0510 IHT INPUT SHAFT VARIABLE SWASH PLATE _ 10 CC VARIABLE DISPLACEMENT PUMP _ CYLINDER BLOCK ASSEMBLY _ CYLINDER BLOCK ASSEMBLY 10 CC FIXED FIXED DISPLACEMENT ANGLE DISPLACEMENT MOTOR CHECK VALVE CHECK VALVE FILTER ASSEMBLY BYPASS ACTUATOR 2 RESERVOIR LI OY TRANSAXLE HOUSING 7 DIFFERENTIAL ASSEMBLY
39. otor 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 EXTERNAL FEATURES 310 0510 FRICTION ae RAN PACK BELT KEEPER e RER ARM IE _ BRAKE DISC ADJUSTING PUCK BYPASS ARM Friction Pack Option Return to Neutral Option FILL PORT AXLE CLIP AXLE CLIP EXPANSION TANK AXLE SHAFT ge Fe SHAFT e AXLE CLIP AXLE CLIP 4 310 0510 IHT MODEL RECOGNITION 7 00 SQ o O 618 0319 104 1760
40. p 250 X 750 X 250 TC Filter Seal Lip 625 X 1 0 X 25 Base Filter O Ring 299 x 505 x 103 Actuator Bypass Kit Expansion Tank Rod Bypass Actuator Kit 60T Bull Gear Diff Pins Arm Bypass Gear 60T Retaining Ring 250 External Pin 0 5 OD Seal Lip 250 x 750 x 250 TC Bulletin Bull Gear Flat Washer 63 x 1 0 x 05 Retaining Ring Spring Block Washer Thrust 59 x 79 x 04 20W 50 Oil Brake Yoke Kit Yoke Brake Bolt Sq Hd 5 16 24 Ribbed Disk Brake Brake Puck Puck Plate Brake Actuating Pin Bolt Hex Head 1 4 20 x 2 w patch Bolt Hex Head 1 4 20 x 1 w patch 310 0510 IHT 33 310 0510 EXPLODED VIEW 87 4 85 THICK RACE MUST BE TOWARDS PISTON L 5 B PORT 25 A PORT 127 SEAL amp O RING KIT 6 SEALANT 57 20W 50 OIL 125 THICK RACE MUST BE TOWARDS PISTON 34 310 0510 IHT 310 0510 ITEMS LIST DESCRIPTION No DESCRIPTION Main Housing Assembly Nut Castle 5 16 24 Main Housing Machined Cotter Pin 3 32 x 3 4 Bushing 865 x 985 x 790 Compression Spring Brake Anti Drag Pin Standard Headless Washer HT 51 x 1 0 x 03 Side Housing Assembly Flat Washer 34 x 88 x 06 Side Housing Machined Oil Seal 625 x 1 0 x 25 Bushing 865 x 985 x 790 Check Plug Assembly 027 Bleed Washer B port Bushing 624 x 719 x 562 Fitting 5 16 SAE 5 32 Tube Center Section Assembly Hose Expa
41. replace linkage Page 9 Adjust brake to proper setting Page 13 Repair or replace drive belt or pulley Page 9 Fill to proper level or change oil Page 10 Reduce vehicle loading Page 9 Repair or replace valve or linkage Purge hydraulic system Page 11 UNIT OPERATING HOT Debris buildup around transaxle Brake setting incorrect Cooling fan damaged Oil level low or contaminated oil Excessive loading Air trapped in hydraulic system Clean off debris Page 9 Adjust brake to proper setting Page 13 Repair or replace cooling fan Fill to proper level or change oil Page 10 Reduce vehicle loading Page 9 Purge hydraulic system Page 11 TRANSAXLE LEAKS OIL Damaged seals housing or gaskets Air trapped in hydraulic system Replace damaged component Purge hydraulic system Page 11 310 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 1 Check the vehicle operator s manual for the recommended load ratings Insure the current application does not exceed load rating 2 Check oil level in accordance with Figure 4 Page 10 3 Inspect the vehicle drive belt idler pulley s and idler spring s Insure t
42. ro 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 displace ment of 10cc per revolution The variable dis placement pump features a trunnion mounted swashplate with a direct proportional displace ment 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 p
43. rs Refer to page 20 Remove the motor shaft and bypass rod See page 21 Remove the retaining ring 12 and shaft seal 13 Discard the seal Remove the washer 11 input shaft as sembly 9 10 and 14 block thrust washer 56 and block spring 55 INSPECTION 1 Inspect the input shaft components for wear or damage ASSEMBLY 1 2 9 Install the axle differential Install the block thrust washer 56 and spring 55 onto the input shaft 9 Ensure that the pump block is aligned con centrically with the center section running face Insert the input shaft 9 with bearing 14 and retaining ring 10 into the pump block assembly NOTE Do not force the shaft and bearing as damage may occur If alignment is correct the shaft assembly will fit into place Install the washer 11 seal 13 and retain ing ring 12 Install the motor shaft amp bypass rod See page 21 amp reduction gears Refer to page 20 Install the side housing Refer to page 19 Install new seals in the side housing See page 18 Fill the transaxle with oil See page 10 10 Install the control arm and friction pack See page 17 11 Install the brake assembly and bypass arm See page 16 22 310 0510 IHT Refer to Figures 15 24 DISASSEMBLY Pump Block 1 Remove the brake assembly and bypass arm See page 16 Remove the control arm and friction pack See page 17 Drain the
44. stall the locating pins 83 if not already installed Install the side housing 2 while aligning the bypass rod into its side housing bore Use care not to smear the sealant bead Install the torque strap screw 8 Tighten the screw according to the specifications in Table 5 Install the side housing screws 7 Refer to the screw tightening pattern in figure 11 and torque specs in Table 5 Install the remaining seals Refer to page 18 Remember to use a seal protector dur ing installation 8 Fill the transaxle with new oil See page 10 9 Install the control arm and friction pack See page 17 10 Install the bypass arm and brake assembly See page 16 Figure 11 Side Housing Assembly 310 0510 IHT 19 AXLE SHAFT DIFFERENTIAL amp REDUCTION GEARS Refer to Figure 12 DISASSEMBLY 1 Remove the brake assembly and bypass arm See page 16 2 Remove the control arm and friction pack See page 17 3 Remove the oil from the transaxle See page 10 4 Remove the side housing See page 19 5 Remove the axle assembly 36 sleeve bearing 31 and washer 33 6 Remove the center block bearing 54 earlier models differential cross shaft s 39 and miter gears 38 7 Remove the bull gear 30 8 Remove the reduction gears 28 amp 29 jack shaft pin 41 and washers 72 INSPECTION 1 Inspect the axle sleeve bearing and washer for wear or damage Replace as necessary 2 Inspec
45. t the differential cross shaft center 20 block bearing and miter gears for wear damage New Bull Gear Differential Assembly This is a direct replacement for the assembly illustrated to the right 3 Inspect the bull gear for wear or damage 4 Inspect the reduction gears shaft and 5 A 1 washers Inspect the housing bores SSEMBLY Reassemble and install the reduction gears 28 amp 29 jack shaft pin 41 and washers 72 Install the bull gear 30 Reassemble and install the center block bearing 54 earlier units differential cross shaft s 39 and miter gears 38 Install the washer 33 sleeve bearing 31 and axle assembly 36 Install the side housing See page 19 Install the outer sleeve bearing 32 axle seal 34 see page 18 and retaining ring 12 Install all remaining seals See page 18 Fill the unit with oil See page 10 Install the control arm and friction pack See page 17 10 Install the brake assembly and bypass arm Figure 12 Axle Shaft Differential amp Reduction Gears earlier bull gear shown See page 16 310 0510 IHT Refer to Figure 13 DISASSEMBLY 1 Remove the brake assembly and bypass arm See page 16 2 Remove the control arm and friction pack See page 17 3 Drain the oil from the transaxle See page 10 4 Remove the side housing See page 19 5 Remove the axle shaft differential and re duction gears
46. ter section See Fig 19 After applying thread adhe sive insert the center section mounting screws 44 while holding downward pres sure on the center section assembly 3 Fig 23 310 0510 IHT HYDRAULIC COMPONENTS 13 Tighten the center section mounting screws 44 to the proper torque Refer to Table 5 Swashplate Pump Block 14 See Fig 18 Install the pump thrust bear ing 19 in the trunnion machined swash plate 4 NOTE Place the thin race of the bearing towards the swashplate The thick race must face the pistons 15 See Fig 16 Place the pump block as sembly 5 pistons down on top of the thrust bearing in the swashplate 4 16 Coat the pump running surface with clean motor oil 17 Care must be taken to prevent the scaring or scratching of the center section sealing face during this step Insert the short shaft side of the swashplate pump block assem bly Fig 24 into the housing while simulta neously compressing the pistons in the block NOTE To assist in the installation of 5 these components insert the assembly un til 74 of the pump block is covered by the Figure 16 center section Then slightly angle the trun nion shaft end away while pressing the short swashplate shaft into its pocket 18 Install the input shaft See page 22 19 Install the bypass rod See page 21 20 Install the axle shaft differential and reduc tion gears Refer to page 20
47. ure which overcomes the total resistance in a system including all losses Valve A device which controls fluid flow direction pressure or flow rate Variable Displacement Pump A pump in which the displacement per cycle can be varied Volumetric Displacement The volume for one revolution 310 0510 IHT 37 Gase EETC 2008 HYDRO GEAR Printed in U S A Rev P1
48. vity The thick race must face the pistons Center Section 3 10 11 12 See Fig 21 Install the new filter base 46 onto the center section 3 Install the check plugs 23 amp 75 in their correct location into the center section 3 Tighten the check plugs according to Table 5 Install the bypass spring 43 into the filter base 46 Install the deflector 107 into the underside of the filter 45 Install the bypass actuator 47 into the un derside of the deflector 107 Hold the stem of the bypass actuator 47 from the top of the filter 45 to retain the deflector 107 and bypass actuator 47 in place when snapping the filter 45 onto the filter base 46 NOTE Filter installation is best accomplished by using the spacer 65 Page 32 as an assembly tool over each of the 4 snaps while lightly tapping with a rubber mallet Excessive force will result in damage to the plastic filter components See Figures 13 amp 23 Install the motor shaft 24 pinion gear 27 and flat washers 52 amp 108 into the center section 3 Assemble the motor block assembly 5 onto the motor shaft 24 See Fig 23 Install the motor shaft center section and motor block assembly so that the block pistons contact the thrust bearing race NOTE Hold in place and insure all pistons are still positioned correctly in the cylinder bore by confirming spring bias against the cen
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