2200 Series Service Manual
Contents
1. OIL LEVEL in HH Figure 4 Fluid Level and Fill Port 310 2200 2 9 PURGING PROCEDURES Due to the effects air has on efficiency in hydro static drive applications it is critical that it is purged from the system These purge procedures should be implemented 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 sys tems The resulting symptoms in hydrostatic systems may be 1 Noisy operation 2 Lack of power or drive after short term op eration 3 High operation temperature and excessive expansion of oil 10 Before starting make sure the transaxle trans mission is at the proper oil level If it is not fill to the specifications outlined on Page 9 Figure 4 The following procedures should be performed with the vehicle drive wheels off the ground then repeated under normal operating conditions 1 With the bypass valve open and the engine running slowly move the directional control in both forward an2. Ne 8 u rrr g gggggx gr r rwwwwa Em 9 Purging Proceduro 10 Return to Neutral Seting YY e DD DD 11 ee 13 How To Use This SOCOM is d za Va yess 13 Generallnstfruclionms 13 Transaxle REMOVAL 13 Limited Disassembly 0000 rr nnn nner x na kanan k aw nawa E Eaa 13 TOOIS ANG ES 14 Control Arm and Bypass os 15 Seal Kit Replacement arrimer a aa a E Aa E E Ai 16 Cog Brake and Side HOUSING as 17 Axle Shaft Reduction Gears and Expansion Plate pt 18 Motor Shafta rrr nv 19 Input Shaft and Bypass ROQ E E N 20 Hydraulic Componenis eee sineira EEEE EEEE NEEE 21 25 Transaxle INStallation 25 Assembly After a Complete Teardown pp 26 SealantApplicatiom es 27 Parts list 28 29 Glossaryof Terms sas NU S n h HU ee eee 30 31 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 cus tomers and the industry as a world class sup plier and the quality leader in eve
3. FLUID VOLUME AND LEVEL Fluid volume information is provided in Table 4 Certain situations may require additional fluid to be added or even replaced Refer to Page 4 and Figure 4 for the proper fill port location Fill the 310 2200 so the oil level is 75 1 50 19 38 mm below the oil fill port Recheck the fluid level once the unit has been operated for approximately 1 minute Purging will be required Refer to the purging procedures on Page 10 310 2200 EZT FLUID CHANGE FLUID CHANGE PROCEDURE This transaxle is factory filled sealed and does 5 Fill the transaxle at the oil fill port according not require oil maintenance However in the to Figure 4 event of oil contamination or degradation oil addition or change may alleviate certain perfor mance problems 7 Purging will be required Refer to the purg ing procedures on Page 10 6 Install the oil fill port fitting 1 Remove the transaxle from the vehicle 8 Recheck the fluid level once the unit has been Clean the oil fill port area of any debris operated for approximately 1 minute 2 3 Remove the oil fill port fitting 4 Position the transaxle so the oil will drain completely out of the housing Table 4 Fluid Volumes for the 310 2200 EZT Fluid Description Volume 20W50 engine oil 54 1 fl oz 1600 ml to 57 5 fl oz 1700 ml FILL PORT 0 75 1 50 19 38 Depth at50 100F 10 38C
4. 34 Use a seal protector when in stalling the input shaft seal 5 N Deburr the end of the bypass rod Install the bypass rod 15 retaining ring 14 seal 13 and retaining ring 16 Install the motor shaft See page 19 Install the reduction gears See page 18 Install the side housing See page 17 Install new seals in the side housing See page 16 10 Fill the transaxle with oil See page 9 11 Install the bypass arm and control arm See page 15 Figure 11 Input Shaft and Bypass Rod Assembly 310 2200 EZT Refer to Figures 12 21 Disassembly 1 Remove the bypass arm and control arm See page 15 Drain the oil from the transaxle See page 9 Remove the side housing See page 17 Remove the reduction gears See page 18 Remove the motor shaft See page 19 9 A V N Remove the input shaft and bypass rod See page 20 7 See Figure 12 Remove the swashplate 19 and pump cylinder block 4 as one as sembly NOTE Removal will be aided by ap plying a small amount of pressure on the trun nion mounted swashplate towards the cen ter section Also note that the control arm 23 page 28 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 8 See Figure 13 Disassemble the pump cyl inder block 4
5. SEAL KIT REPLACEMENT Before disassembly wipe the unit free of any debris to avoid contamination Refer to Figure 7 Input Seal 1 Remove the input pulley from the input shaft 2 Remove the seal retaining ring 34 Carefully pull the input seal 33 out of the housing bore with a hook type tool Care must be taken to avoid damage to the hous ing bore or shaft sealing area 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 7 The seal should seat against the spacer 8 Install the seal retaining ring 34 and make sure it is fully seated in its groove Output Seal 1 The seal 51 can be replaced by following steps 2 6 of the procedure used to replace the input seal 2 Install the retaining ring 34 and make sure it is fully seated in its groove Motor Shaft Seal 16 Remove the cog brake See page 17 The seal 10 can be replaced by following steps 3 6 of the procedure used to replace the input shaft Trunnion Seal 1 Remove the control arm and any attachments to the control arm See page 15 2 The seal 20 can be replaced by following steps 3 6 of the procedure used to replace the input shaft Bypass Seal 1 Remove the bypass arm and any attach ments to the bypass
6. 23 41 Nm 25 50 Ib in 3 6 Nm 360 520 Ib in 41 59 Nm 80 120 Ib in 9 14 Nm 85 120 Ib in 10 14 Nm 100 160 lb ft 136 217 Nm Description Screw 1 4 20 x 1 25 Screw 5 16 24 x 1 Stud 5 16 24 Screw 3 8 24 x 2 5 Check Plug Assembly Screw 10 32 x 0 50 Lock Nut 1 2 x 20 Bolt 1 4 20 x 1 Screw 5 16 24 x 1 00 Nut Hex 3 4 16 Lock 310 2200 EZT CONTROL ARM AND BYPASS ARM Refer to Figure 6 Disassembly 1 Loosen and remove the lock nut 26 and flat washer 24 Discard the lock nut 26 and flat washer 24 Remove the torx head screw 25 from the directional control Remove control arm 23 and pucks 22 Discard the pucks Remove the bypass arm retaining ring 18 and bypass arm 17 Discard the retaining ring If necessary remove and replace the con trol arm stop stud 21 Inspection As Inspect the control arm stop stud 21 for wear or damage Inspect the control arm 23 for wear or dam age Inspect the bypass arm 17 for wear or dam age Assembly Install the bypass arm 17 onto the bypass rod Secure the bypass arm with a new re taining ring 18 Replace the control arm stop stud 21 if removed Torque according to specifications in Table 6 on page 14 Install the control arm 23 Install the control arm screw 25 Refer to Table 6 for screw torque specifications Figure 6 Control Arm and Bypass Arm 310 2200 EZT
7. O HYDRO GEAR FORWARD MOTION THROUGH FORWARD THINKING 310 2200 EZT Integrated Zero Turn Transaxle Service and Repair Manual BLN 51856 D ber 2008 TABLE OF CONTENTS Section Page TO OG 1 Description and la kad kak a va ba la kl kk ka k r 2 ntroduGti rY 2 General DESCHPTOMN 2 Hydraulic Schemalie u as E E A EE E E SS 3 External Features 310 2200 pp 4 Technical SPSCHIGALONS 5 PROGUCT AEMUTGCATION 5 Safety o u uw u u se em tees E cea cat nadcnadauddnatanedanctaenneetensieecteneuetes 6 Personal Safely ae 6 ToolSaiely Ax J DI DEE E DD DD r r 6 Work Area Safely 2 ea yA wa H k k w da anl a ak k aa a a k aa kul kk A ak d b a aa S aa k 6 ServiGing Safely ee 6 Troubleshooting a u ua us upssspspapapuscpasapasakasapisapisapasapiyaqkayshasqhapqhawsaahaqawsasasa sasa casas Es ma 7 Service and MaI te nanc dl ksalk disala klalabakak alal ak all akan ab kak ai anan ka kada ya qasa sasa b d k a a a saa ail 8 ExternalMalnteTiallG 8 Service and Maintenance Procedure qu We kr nen ka Weke z 8 De S N np DDMDMDMDMaNMDMIDMIEoNoE N E D ID DJ E ED EE 8
8. arm See page 15 Remove the seal retaining ring 16 Remove the bypass rod keeping the retaining ring 14 attached Remove the bypass rod seal 13 Deburr the bypass rod Install the seal 13 Install the bypass rod with the retaining ring 14 attached Install the seal retaining ring 16 Figure 7 Seal Kit Replacement 310 2200 EZT COG BRAKE AND SIDE HOUSING Refer to Figure 8 Disassembly 1 Remove the control arm and bypass arm See page 15 Remove the oil from the transaxle See page 9 Remove the brake arm assembly 55 re taining ring 14 and cog brake disc 100 Remove the lip seal 10 Remove the housing screws 9 Pull the side housing 2 leaving the axle 49 and bull gear 46 assembled in the main housing It may be necessary to use screw drivers at the pry points to break loose the sealant positions H L and M P Figure 8 Clean off all the old sealant on the side and main housings Take care not to damage the sealing surfaces A wire brush and solvent is effective Inspection 1 Check the brake arm brake disc for exces sive wear or teeth damage Replace if nec essary 2 3 Check for excessive looseness at the arm pivot point Inspect the bearing and bushing areas in the side housing Assembly 1 Apply bead of sealant around the perim eter of the side housing face See sealant pattern on page 27 Install the locating pins 8
9. from the swashplate 19 9 See Figure 14 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 Inspect the pistons A piston springs C and thrust washers B for excessive wear or damage NOTE Thrust washers may be held in place in the piston by residual oil 10 Reassemble the pistons springs and wash ers into the cylinder block and set aside 11 See Figure 15 Remove the thrust bearing assembly 35 from the swashplate 19 310 2200 EZT HYDRAULIC COMPONENTS Center Section Filter 12 See Figure 16 Remove the center section mounting screws 12 NOTE The center section is under motor block piston spring pressure These screws are factory installed to 700 Ib in 80 Nm and use an anaerobic thread adhesive A breaker bar will be re quired at this step Clean the internal threads of the mounting holes with compressed air 13 Remove the center section and filter assem bly 57 Figure 17 NOTE Bypass plate Fig ure 17 may slide out of the center section 14 Remove the filter cover by pressing in and down on the filter cover tabs Discard the cover 15 Note the location of both check plugs 56 before removal for correct replacement dur ing reassembly Remove and inspect the check plug assemblies 56 for debris or damage 16 Remove the filter base 61 and dis
10. item reference numbers in each illustration are for assembly instruc tions only See page 29 for part names and de scriptions A complete exploded view and item list of the transaxle is provided at the end of the repair section GENERAL INSTRUCTIONS Cleanliness is 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 in stallation lightly lubricate all seals O rings and 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 310 2200 EZT 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 in BLN 51427 CD IMPORTANT When internal repair is performed on the 310 2200 EZT the filter assembly must be replaced TRANSAXLE REMOVAL It is necessary to remove the 310 2200 fro
11. oil supply for the hydraulic sys tem of the 310 2200 EZT is also utilized for lu bricating the components of the final drive as sembly 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 pis tons 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 310 2200 EZT increase and cause a higher speed 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 transaxle housing then is pulled back into one of the check valves depending upon the direc tion of vehicle operation All of this oil must pass through an internal filter The motor cylinder block mounts onto a splined motor shaft which drives the gear train The bypass feature in the 310 2200 has a me chanical lever which lifts t
12. through the filter by a positive head on the fluid in the housing expansion tank with an assist by the negative pressure created in the pump pistons as they operate The check valves in the center section are used to control the make up flow of the fluid to the low pressure side of the loop Acam style block lifting bypass is utilized in the 310 2200 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 BYPASS FILTER Figure 1 Hydraulic Schematic 310 2200 EZT 310 2200 EZT HYDRAULIC FLOW SCHEMATIC INPUT SHAFT VARIABLE SWASH PLATE 10 CC VARIABLE DISPLACEMENT PUMP E CYLINDER BLOCK ASSEMBLY MOTOR BLOCK B 10 CC MOTOR FIXED SWASH yz CHECK VALVE FILTER ASSEMBLY _ ZZZZZZZZZ22223 10 CC FIXED DISPLACEMENT MOTOR LIL PA RESERVOIR x TRANSAXLE HOUSING a SIPHONING EXPANSION TANK Figure 2 Hydraulic Flow Illustration HYDRAULIC SCHEMATIC Figure 2 provides an illustration of the hydraulic oil circuit The
13. APPNG SSCS arm PARKING BRAKES x waster pour 14 20x wenen SSCS feuse 260x sax a gt ee CENTER SECTION MACHNED L eusina 707 x zax 5 x usss O CT BOUT HEX FLANGE eaa OOOO check PLUG ASSEMBLY SCS _ ASSewBLy erook OO D RING RETANNG 375 ExT PUSH O rue ease E C C C s s nmax CT HEX WASHER HEAD TAPPING SCREW 1420X 25 29 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 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 Adevice 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
14. ARD HEADLESS SEAL LIP 375 X 75 X 25 2 ASSEMBLY SIDE HOUSING SIDE BUSHING 624 X 719 X 562 BUSHING 865 X 985 X 790 PLATE BYPASS ASSEMBLY PUMP BLOCK BLOCK CYLINDER PISTON SPRING COMPRESSION WASHER THRUST SPACER ASSEMBLY MOTOR BLOCK PLUG 9 16 18 PIN STAINLESS HEADLESS HFHCS 1 4 20 X 1 25 SELF TAPPING SEAL LIP 625 X 1 000 X 250 BOLT HEX FLANGE 3 8 24 X 2 5 13 SEAL LIP 375 X 75 X 25 14 RING RETAINING 375 EXT 15 ROD BYPASS 16 RING RETAINING 750 INT 17 ARM BYPASS 18 RING RETAINING 375 EXT PUSHNUT 19 SWASHPLATE TRUNNION MACHINED 20 SEAL LIP 18 X 32 X 7 21 STUD 22 PUCK FRICTION 23 ARM CONTROL 24 WASHER FLAT 11 32 ID X 7 8 OD X 1 16 25 TWHCS 5 16 24 X 1 0 26 NUT HEX LOCK 5 16 24 UNJF 27 SPRING HELICAL COMPRESSION 28 WASHER 591 X 787 X 040 29 SHAFT INPUT 30 BEARING BALL 17MM ID X 40MM OD X 12MM 31 RING RETAINING WIRE 561 ID 32 SPACER 33 SEAL LIP 17 X 40 X 7 34 RING RETAINING 35 BEARING THRUST 30 X 52 X 13 36 WASHER FLAT 5 8 ID X 1 0 OD X 05 37 RING RETAINING 38 GEAR PINION 13T 39 SHAFT MOTOR 40 WASHER MOTOR SHAFT 71 ID X 1 16 OD X 04 41 WASHER HT 5 ID X 1 0 OD X 032 42 GEAR 10T 48T 43 GEAR 10T JACKSHAFT 44 PIN JACKSHAFT 45 RING SPIRAL RETAINING 46 GEAR 52T BULL EN aja NS l 310 2200 EZT 310 2200 ITEMS LIST DESCRIPTION BEARING SLEEVE EXPANSION SS 10 32 x 12 SELFT
15. OEM s control linkage at the control arm Refer to Figure 5 3 Start the engine and increase the throttle to full engine speed gt lt AXLE ROTATION B AXLE ROTATION A 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 4 Check for axle rotation If the axle does not rotate go to Step 5 If the axle rotates go to Step 6 5 Stop the vehicle s engine Reattach and ad just the OEM linkage according to Step 3 and Step 4 Stop the vehicle engine Refer to Figure 5 6 Note the axle directional movement Stop the vehicle engine Loosen the RTN adjustment screw until the control arm can be rotated Ro tate the control arm in the opposite direction of the wheel rotation in 5 degree increments Tighten the RTN adjustment screw Refer to table 6 Required Torque values page 14 Re check according to steps 3 and 4 Stop the ve hicle engine Reattach and adjust the OEM link age according to the OEM manual Recheck ac cording to steps 3 and 4 Refer to Figure 5 310 2200 EZT RTN Adjustment Screw NOTES 310 2200 EZT SECTION 5 REPAIR HOW TO USE THIS MANUAL Each subassembly illustrated in this section is illustrated with an exploded view showing the parts involved The
16. an day of year unique number for that model for that day Type of Product and Build Information Figure 3 Configuration Label 310 2200 EZT 5 SECTION 2 SAFETY A This symbol points out important safety instructions which if not followed could endan ger the personal safety and or property of your self and others Read and follow all instruc tions in this manual before attempting mainte nance 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 in personal injury or damage to the equip ment Before servicing or repairing the 310 2200 EZT fully read and under stand the safety precautions described in this section PERSONAL SAFETY Certain safety precautions must be observed while servicing or repairing the 310 2200 EZT This section addresses some of these precau tions but must not be considered an all inclusive source on Safety information This section is to be used in conjunction with all other safety mate rial 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 equip ment and the hazards associated with it Do not place speed above safety Notify your supervisor whenever you feel there is any hazard involving the e
17. and wear 6 Inspect all bearing bushing and wear areas in the housing Assembly Motor Block 1 22 See Figure 19 Turn the housing 1 so the motor thrust bearing cavity is facing up This will assist in the installation of the motor thrust bearing assembly 35 keeping it in the bearing cavity during installation of the center section assembly 57 Figure 17 Insert the thrust bearing 35 in the housing 1 NOTE Place the thin race of the bear ing towards the housing bearing cavity The thick race must face the pistons Center Section Filter 3 See Figure 18 Install the new filter base 61 onto the center section 57 It will be necessary to clean the check plugs prior to re assembly Install the check plugs 56 in their correct location into the center section 57 Tighten the check plugs accord ing to Table 6 Align the tabs on the filter cover with the slots in the filter base and carfully press the cover onto the base until the tabs snap into place Insure the bypass plate Figure 18 is located properly in the center section See Figures 10 amp 20 Install the motor shaft 39 pinion gear 38 and flat washers 36 amp 40 into the center section 57 Assemble the motor block assembly 4 onto the motor shaft 39 See Figure 20 Install the motor shaft cen ter section and motor block assembly into the housing so that the motor block pistons con tact the thrust beari
18. ated Zero Turn Transaxle EZT This manual includes the EZT s general descriptions hy draulic schematics technical specifications ser vicing and troubleshooting procedures The transaxle normally will not require servicing during the life of the vehicle in which it is in stalled Should other servicing be required the exterior of the transaxle will need to be thor oughly cleaned before beginning most proce dures Do not wash the transaxle while it is hot Do not use a pressure washer to clean the unit GENERAL DESCRIPTION The 310 2200 is a self contained unit designed for the transfer and control of power It provides an infinitely variable speed range between zero and maximum in both forward and reverse modes of operation This transaxle uses a variable displacement pump with a maximum displacement of 10cc per revolution and motor with a fixed displacement of 10cc per revolution The variable displace ment 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 INPUT SHAFT Ns VENT pump and thus reverses the direction of the mo tor 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 2200 has a self contained fluid supply and an internal filter The fluid is forced
19. aulic system Fill to proper level or change oil Page 9 Reduce vehicle loading Page 8 Repair or replace loose parts Repair or replace linkage Purge hydraulic system Page 10 UNIT HAS NO LOW POWER Engine speed low Control linkage bent or out of adjustment 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 replace linkage Page 8 Repair or replace drive belt or pulley Page 8 Fill to proper level or change oil Page 9 Reduce vehicle loading Page 8 Repair or replace linkage Purge hydraulic system Page 10 UNIT IS OPERATING HOT Debris buildup around transaxle Cooling fan damaged Oil level low or contaminated oil Excessive loading Air trapped in hydraulic system Clean off debris Page 8 Repair or replace cooling fan Fill to proper level or change oil Page 9 Reduce vehicle loading Page 8 Purge hydraulic system Page 10 TRANSAXLE LEAKS OIL Damaged seals housing or gaskets Air trapped in hydraulic system 310 2200 EZT Replace damaged component Purge hydraulic system Page 10 SECTION 4 SERVICE AND MAINTENANCE NOTE Any servicing dealer attempting a warranty repair must have prior ap proval before conducting maintenance of a Hydro Gear product unless the servic ing dealer is a current Authorized Hydro Gear Service Center EXTERNAL MAINTENANCE Re
20. card it NOTE The filter base is included in the filter kit to be installed during reassembly of the unit Motor Block 17 See Figure 19 Remove the motor cylinder block assembly 4 from the housing 1 18 Disassemble the motor cylinder block as sembly 4 Check each piston for proper operation by pressing the pistons in and re leasing them in the block bore Disassemble the motor cylinder block Check for piston block wear in the cylinder bore Inspect the pistons piston springs and thrust washers for excessive wear or damage NOTE Thrust washers may be held in place in the piston by residual oil 19 Reassemble the pistons springs and thrust washers into the cylinder block and set aside 21 20 Remove the thrust bearing assembly 35 from the housing 1 Inspect the thrust bear ing and thrust bearing cavity in the housing Inspection 1 Inspect the pump cylinder block running sur face for wear or damage Inspect the swashplate and thrust bearing assemblies for wear or damage Inspect the center section block running sur faces 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 sur face for damage
21. cay A 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 specific 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 Avalve controlling the replenishing flow of fluid from a charge circuit to the closed loop in a fluid power system System Pressure The pressure which overcomes the total resistance in a system including all efficiency losses Valve A device which controls fluid flow direction pressure or flow rate Variable Displacement Pump A pump in which the displacement per revolution can be varied Volumetric Displacement The volume for one revolution 310 2200 EZT 31 NOTES 310 2200 EZT 310 2200 EZT NOTES O HypRO GEAR
22. d reverse directions 5 or 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 the engine 3 It may be necessary to repeat Steps 1 and 2 until all the air is completely purged from the system When the transaxle moves for ward and reverse at normal speed purging is complete 310 2200 EZT RETURN TO NEUTRAL SETTING A WARNING POTENTIAL FOR SERIOUS INJURY Inattention to proper safety operation or maintenance procedures could result in personal injury or damage to the equip ment Before servicing or repairing the 310 2200 EZT fully read and under stand the safety precautions described in this section The return to neutral mechanism on the transmis sion is designed to set the directional control into a neutral position when the operator releases the vehicle hand control Follow the procedures be low to properly adjust the return to neutral mecha nism on the transaxle 1 Confirm the transaxle is in the operating 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 link age control and the transaxle return arm 2 Remove the Original Equipment Manufacturer s
23. gular external maintenance of the 310 2200 EZT should include the following 1 Check the vehicle operator s manual for the recommended load ratings Insure that the current application does not ex ceed load rating 2 Check oil level in accordance with Figure 4 Page 9 Inspect the vehicle drive belt idler pulley s and idler spring s Insure that no belt slip page can occur Slippage can cause low in put speed to the transmission 4 Inspect the vehicle control linkage to the di rectional control arm on the transaxle Also insure that the control arm is securely fas tened to the trunnion arm of the transaxle 5 Inspect the bypass mechanism on the transaxle and the vehicle linkage to insure that both actuate and release fully SERVICE AND MAINTENANCE PROCEDURES Some of the service procedures presented on the following pages can be performed while the 310 2200 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 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 9 0 cSt 55 SUS at 230 F 110 C and an API Classification of SL is recommended 20W50 engine oil has been selected for use by the fac tory and is recommended for normal operating procedures
24. he motor block off of the center section running surface This allows oil flow from the cylinder blocks to be discharged EXTERNAL FEATURES 310 2200 AXLE SHAFT BYPASS ARM MAIN HOUSING FILL PORT PULLEY OO J OO SIDE HOUSING COG BRAKE DISC BRAKE ARM INPUT SHAFT S A CONTROL ARM SS e 2 310 2200 EZT TECHNICAL SPECIFICATIONS Technical specifications for the 310 2200 EZT are listed in Table 1 Table 1 Technical Specifications Input Speeds Maximum Tire Diameter Maximum 3000 RPM 20 inch 508 mm Minimum 1800 RPM Weight of Unit Maximum Weight on Drive Tires 29 0 Ibs 13 15 Kg 300 Ibs 136 Kg with 20 Tires 340 Ibs 154 Kg with 18 Tires Table 2 310 2200 EZT Component Options Brake Location Inboard Outboard Brake Type Cog Fiction Dise Control Arm Location Inboard Outboard Control Arrangements Standard Control Arm RTN scissor style 19 2 1 CE PRODUCT IDENTIFICATION The model and configuration of the 310 2200 EZT can be determined from the label shown in Figure 3 HYDRO GEAR BOM Model Sales Drawin 2 186 H1 476 MADE IN U S A Date Serial Number Juli
25. if not already in stalled Install the side housing 2 Use care not to smear the sealant bead Install the side housing screws 9 Refer to the screw tightening pattern in Figure 8 and torque specification in Table 6 on page 14 Install the remaining seals Refer to page 16 Remember to use a Seal protector during in stallation Install the brake disc 100 retaining ring 14 and brake arm assembly 55 Fill the transaxle with new oil See page 9 Install the bypass arm and control arm See page 15 Figure 8 Cog Brake and Side Housing Assembly 310 2200 EZT 17 AXLE SHAFT REDUCTION GEARS AND EXPANSION PLATE Refer to Figure 9 Disassembly 1 Remove the bypass arm and control arm See page 15 Remove oil from the transaxle See page 9 Remove the side housing See page 17 Remove the spiral retaining ring 45 bull gear 46 inboard sleeve bearing 48 and washer 47 Remove the reduction gears 42 amp 43 jack shaft pin 44 and washers 41 Remove seal retaining ring 34 seal 51 axle 49 and bushing 50 If necessary remove the expansion plate as sembly 53 NOTE Expansion plate removal will typically destroy the plate Clean all sealant from the expansion plate area Inspection 1 2 Inspect the bull gear for wear or damage Inspect the reduction gears jack shaft pin and washers 3 Inspect
26. ion while pushing the shaft into its bore 15 Install the input shaft and bypass rod See page 20 16 Install the axle shaft reduction gears and ex pansion plate if removed Refer to page 18 17 Install the side housing and brake See page 17 18 Fill the transaxle with new oil See page 9 19 Install the bypass arm and control arm See page 15 310 2200 EZT Figure 13 Figure 14 23 BYPASS PLATE 5 N j Wp CK RACE Figure 15 Figure 18 Figure 16 Figure 19 Figure 17 310 2200 2 24 310 2200 2 SHORT SHAFT Figure 21 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 hard ware 3 Lower the vehicle wheels to the ground and torque the wheel hardware per the vehicle owner s manual 25 ASSEMBLY AFTER A COMPLETE TEARDOWN If the unit has been torn down completely the following summary identifies the assembly procedures necessary to completely as semble the unit Each assembly procedure is located by a page reference The part reference numbers provided in each assembly procedure are keyed to the indi 6 vidual exploded views and are als
27. m the vehicle before performing the repair proce dures presented in this section LIMITED DISASSEMBLY The following procedures are presented in the order in which they must be performed to com pletely disassemble the unit Do not disassemble the unit any farther than is necessary to accom plish the required repairs Each disassembly pro cedure is followed by a corresponding assem bly 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 24 TOOLS AND TORQUES Miscellaneous 310 2200 Service amp Repair Manual Flat Blade Screw Driver 2 Torque Wrench Air Impact Wrench Rubber Mallet Breaker Bar Side Cutters Snips Pliers Needle Nose Table 5 Required Tools Large External Snap Ring Small Internal Snap Ring Operation Side Housing Screws Control Arm Screw Control Arm Stop Stud Center Section Bolts Check Plugs Expansion Plate Screws Fan Pulley Lock Nut Cog Brake Bolt RTN Adjustment Screw Hub Nut 14 Sockets 1 2 3 8 Adapter 3 8 Deep 1 2 Deep 7 16 Deep 9 16 Deep 3 4 Deep 13 16 Deep 7 8 T 25 Torx Head T 40 Torx Head Apex AN 08 Table 6 Required Torque Values Torque 135 185 Ib in 15 21 Nm 230 310 Ib in 26 35 Nm 50 120 Ib in 6 18 Nm 525 700 Ib in 60 80 Nm 200 360 Ib in
28. ng race NOTE Hold in place and insure all pistons are still positioned correctly in the cylinder bore by confirming spring bias against the center section See Figure 16 After applying thread adhe sive insert the center section mounting screws 12 while holding downward pres sure on the center section assembly 57 Figure 20 10 Tighten the center section mounting screws 12 to the proper torque Refer to Table 6 NOTE The center section must be fully seated into the pilot bore before the screws are tightened The center section will not self 310 2200 EZT locate Swashplate Pump Block 11 See Figure 15 Install the pump thrust bear ing 35 in the trunnion machined swashplate 19 NOTE Place the thin race of the bear ing towards the swashplate The thick race must face the pistons 12 See Figure 13 Place the pump block as sembly 4 pistons down on top of the thrust bearing in the swashplate 19 13 Coat the pump running surface with clean motor oil 14 Care must be taken to prevent the scaring or scratching of the center section sealing face during this step Insert the shaft of the swashplate pump block assembly Figure 21 into the housing while simultaneously compressing the pistons in the block NOTE To assist in the installation of these compo nents insert the assembly until 3 4 of the pump block is covered by the center section Then slightly press the shaft end toward the center sect
29. nter section 57 Install the reduction gears See page 18 Install the side housing Refer to page 17 Install new seals Refer to page 16 Fill the transaxle with oil See page 9 Install the bypass arm and control arm See page 15 Figure 10 Motor Shaft 310 2200 EZT INPUT SHAFT AND BYPASS ROD Refer to Figure 11 Disassembly 1 O QO A W N Remove the control arm and bypass arm See page 15 Drain the oil from the transaxle See page 9 Remove the side housing See page 17 Remove the reduction gears See page 18 Remove the motor shaft See page 17 Remove the retaining ring 34 and shaft seal 33 Discard the seal Remove the spacer 32 and input shaft as sembly 29 30 amp 31 Remove the compression spring 27 and washer 28 Remove the rings 14 amp 16 bypass rod 15 and seal 13 Inspection 1 Inspect the input shaft components and by pass rod for wear or damage Assembly 1 20 Visually ensure that the pump block is aligned concentrically with the center section run ning face Install the compression spring 27 and washer 28 Insert the input shaft 29 with bearing 30 and retaining ring 31 into the pump block assembly NOTE Do not force the shaft and bearing as damage may occur If align ment is correct the shaft assembly will fit into place Install the washer 32 seal 33 and retain ing ring
30. o keyed to the complete unit exploded view on page 26 7 1 Install the hydraulic components See pages 21 25 8 2 Install the input shaft and bypass rod See page 20 26 Install the axle shaft reduction gears and expansion plate See page 18 Install the cog brake and side housing See page 17 Fill the transaxle with new oil See page 9 Install the bypass arm and control arm See page 15 Install the transaxle onto the vehicle Perform the purge procedures listed on page 10 310 2200 EZT SEALANT APPLICATION NOTE Prior to applying the new sealant the old sealant must be removed from all sur faces small consistent bead of the sealant around the housing face will be sufficient Use spar ingly The illustration below indicates the correct areas SIDE ASSEMBLY SEALANT PATH EXPANSION PLATE SEALANT PATH 310 2200 EZT 27 310 2200 EXPLODED VIEW 1 BRAKE AND CONTROL ARM CAN BE ON EITHER SIDE 2 LH SIDE SHOWN RH SIDE IS A MIRROR IMAGE 58 SEALANT TUBE 10 3 oz 145 ASSEMBLY HUB PULLER ITEMS NOT SHOWN 11 OIL 20W50 52 KIT SEAL NOTES Kek A S Figure 22 310 2200 28 310 2200 EZT DESCRIPTION 1 ASSEMBLY MAIN HOUSING HOUSING MAIN BUSHING 865 X 985 X 790 PLATE EXPANSION SCREW 10 32 X 1 2 SELF TAPPING PIN STAND
31. quipment or the per formance of your job Never allow untrained or unauthorized person nel to service or repair the equipment Wear appropriate clothing Loose or hanging clothing or jewelry can be hazardous Use the appropriate safety equipment such as eye and hearing protection and safety toe and 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 exten sion cords or similar trip hazards should be re moved 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 Some cleaning solvents are flammable Use only approved cleaning materials Do not use explo sive 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 app
32. ropri ate containers 310 2200 EZT 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 2200 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 pump is malfunctioning Table 3 below provides a troubleshooting checklist to help determine the cause of operational problems Table 3 310 2200 EZT 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 8 Repair or replace drive belt or pulley Page 8 VEHICLE DOES NOT DRIVE TRACK STRAIGHT Vehicle tires improperly inflated Control linkage bent or out of adjustment Bypass assembly sticking Refer to vehicle manufacturer suggested pressure Repair or replace linkage Pages 8 and 11 Repair or replace bypass Page 20 UNIT IS NOISY Oil level low or contaminated oil Excessive loading Loose parts Bypass assembly sticking Air trapped in hydr
33. rything we do This Service and Repair Manual is designed to provide information useful in servicing and troubleshooting the Hydro Gear 310 2200 EZT Integrated Zero Turn Transaxle 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 a good shop practice that your service area be equipped with the proper tools and the mechanics be supplied the latest information available All repair procedures il lustrated in this guide are suggested but pre ferred methods of repair 310 2200 EZT Repair procedures require that the transaxle unit be removed from the vehicle This is not a certification test or study guide for a certification test If a technician is interested in certification they should contact an agent representing the ESA Engine Service Associa tion at 610 363 3844 or their Hydro Gear Central Service Distributor Many distributors will be hosting certification testing These study guides will cover most of the products and manu facturers in our industry For more information about Hydro Gear or our products please contact your Central Service Distributor or call our Customer Service De partment at 217 728 2581 SECTION 1 DESCRIPTION AND OPERATION INTRODUCTION The purpose of this manual is to provide infor mation useful in servicing the Hydro Gear Inte gr
34. the charge circuit Check Valve A valve whose primary function is to restrict flow in one direction Closed Loop Asealed 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 mechanically generated 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 Hydrostatic Transaxle A multicomponent assembly including a gear case and a hydrostatic transmission 30 310 2200 EZT Hydrostatic Transmission The combination of a hydraulic pump and motor in one housing to form a device for the control and transfer of power Inlet Line A supply line to the pump Integrated Zero Turn Transaxle 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 De
35. the axle shaft bearing and bushing 4 Inspect the expansion plate Assembly 1 9 Apply a small bead of sealant to the sion plate area of the housing See page 27 Install the expansion plate 53 Torque the screws according to Table 6 Reassemble and install the reduction gears 42 amp 43 jack shaft pin 44 and washers 41 Install the bull gear 46 retaining ring 45 bearing 48 and washer 47 onto the axle 49 Install the axle 49 and bushing 50 into the housing 1 Install the axle seal 51 and retaining ring 34 Install the side housing See page 17 Install all remaining seals See page 16 Fill the transaxle with oil See page 9 Install the bypass arm and control arm See page 15 18 Figure 9 Axle Shaft Reduction Gears and Expansion Plate 310 2200 EZT Refer to Figure 10 Disassembly 1 N Remove the control arm and bypass arm See page 15 Drain the oil from the transaxle See page 9 Remove the side housing See page 17 Remove the reduction gears See page 18 Remove flat washer 36 motor shaft and pin ion gear 39 amp 38 and flat washer 40 Inspection 1 Inspect the motor shaft 39 pinnion gear 38 and flat washers 36 amp 40 for wear or dam age MOTOR SHAFT Assembly 1 ak Insert the motor shaft 39 with the pinnion gear 38 and flat washers 36 amp 40 into the ce
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