Hydro-Gear 310-0510, Service And Repair Manual

Page 1: ...310 0510 0610 0710 Integrated Hydrostatic Transaxle Service and Repair Manual BLN 51260 Dec 2008 ...

Page 2: ...hange 10 Purging Procedures 11 Return to Neutral Setting 12 Brake Maintenance 13 Friction Pack Adjustment 13 Section 5 Repair 14 How To Use This Section 14 General Instructions 14 Transaxle Removal 14 Limited Disassembly 14 Tools and Torques 15 Brake Assembly and Bypass Arm 16 Control Arm and Friction Pack 17 Seal Kit Replacement 18 Side Housing 19 Axle Shaft Differential and Reduction Gears 20 Mo...

Page 3: ...erminology is very important It is necessary and good shop practice that your service area be equipped with the proper tools and the mechanics be supplied with the latest information available All repair procedures illustrated in this guide are suggested but preferred methods of repair Repair procedures require that the transaxle unit be removed from the vehicle This is not a certification test or...

Page 4: ... 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 ...

Page 5: ...Reversing the angle of the swashplate will reverse the direction of oil flow During the operation of the transaxle fluid is lost from the hydraulic loop through leak paths designed into the product for lubrication purposes around pistons under the rotating cylinder blocks etc This lost fluid returns to the transaxle housing then is pulled back into one of the check valves depending upon the direct...

Page 6: ...S 310 0510 Return to Neutral Option Friction Pack Option AXLE SHAFT FILL PORT EXPANSION TANK INPUT SHAFT CONTROL ARM BRAKE DISC FAN BRAKE ARM BYPASS ARM FRICTION PACK ADJUSTING PUCK BELT KEEPER AXLE CLIP AXLE CLIP AXLE CLIP AXLE CLIP ...

Page 7: ...310 0510 IHT 5 MODEL RECOGNITION 618 0319 166768 104 1760 173839 036932 618 0389A ...

Page 8: ...he label shown in Figure 3 Figure 3 310 0510 Configuration Label H Y D R O G E A R SULLIVAN IL U S A I IIII III IIII II II 13054 318 2400 I II IIII IIII III III I II IIII 0 319 Z1 401 Made in U S A Year Built Date Julian day of year Type of Product and Build Information Serial Number unique number for that model for that day Model Number Hydro Gear Ref Number H Y D R O G E A R SULLIVAN IL U S A I ...

Page 9: ...ormance 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...

Page 10: ...ct 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 Corrective Action Possible Cause VEHICLE DOES NOT DRIVE TRACK STRAIGHT Repair or replace linkage...

Page 11: ...s 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 mentioned in the repair section of t...

Page 12: ...l 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 listed 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 lubricat...

Page 13: ...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 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 dir...

Page 14: ... 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 Pag...

Page 15: ...e 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 nu...

Page 16: ...aces 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 th...

Page 17: ...on Pack Wedge Screw 30 70 in lb 3 4 8 Nm 88 Screw Self Tapping 10 32 x 5 Puck Inner Wedge Bolt 42 65 lb in 5 7 Nm 88 Bolt 10 32 x 0 5 Adjusting Puck Screw 250 320 lb in 28 36 Nm 95 Socket Hd CS 5 16 24 x 1 50 RTN Screw 180 240 lb in 20 27 Nm 97 Screw Countersunk 5 16 18 x 1 Bracket Screw 230 310 lb in 26 35 Nm 110 Screw Torx Hd 5 16 18 x 1 50 Fan Pulley Input Shaft Nut 300 460 lb in 34 52 Nm 121 N...

Page 18: ...ove 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 and brake rotor 59 2 Install the ...

Page 19: ...mage 3 Inspect the inner wedge puck 90 4 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 5 2 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...

Page 20: ...at against the sleeve bearing 8 Install the seal retaining rings 12 9 Install the axle clips 93 if applicable Input Seal 1 Remove the input pulley and fan from the input shaft 2 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 any attach ments to the control arm See page 17 2 The seal 17 can be replaced by...

Page 21: ...ad of sealant around the perime ter of the side housing face See sealant pattern on page 28 2 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 3 Install the locating pins 83 if not already installed 4 Install the side housing 2 while aligning the bypass rod into its side housing bore U...

Page 22: ...for wear or damage 4 Inspect the reduction gears shaft and washers 5 Inspect the housing bores ASSEMBLY 1 Reassemble and install the reduction gears 28 29 jack shaft pin 41 and washers 72 2 Install the bull gear 30 3 Reassemble and install the center block bearing 54 earlier units differential cross shaft s 39 and miter gears 38 4 Install the washer 33 sleeve bearing 31 and axle assembly 36 5 Inst...

Page 23: ...nnion gear 27 and flat washers 52 108 for wear or damage 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 52 108 into the center section 3 3 Install the axle shaft differential and ...

Page 24: ...aft components for wear or damage ASSEMBLY 1 Install the block thrust washer 56 and spring 55 onto the input shaft 9 2 Ensure that the pump block is aligned con centrically with the center section running face 3 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 as...

Page 25: ... may be held in place in the piston by residual oil 12 Reassemble the pistons springs and seats into the cylinder block and set aside 13 See Fig 18 Remove the thrust bearing assembly 19 from the swashplate 4 Center Section Filter 14 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 ...

Page 26: ...s the housing bearing cavity The thick race must face the pistons Center Section 3 See Fig 21 Install the new filter base 46 onto the center section 3 4 Install the check plugs 23 75 in their correct location into the center section 3 Tighten the check plugs according to Table 5 5 Install the bypass spring 43 into the filter base 46 6 Install the deflector 107 into the underside of the filter 45 7...

Page 27: ...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 these components insert the assembly un til of the pump block is covered by the 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 pa...

Page 28: ...310 0510 IHT 26 3 46 HYDRAULIC COMPONENTS Figure 21 Figure 19 44 44 Figure 20 124 Post 75 23 43 47 107 45 Figure 22 1 19 5 Axle Horn Figure 23 5 3 24 Figure 24 Swashplate Pump Block Assembly Short Shaft ...

Page 29: ...mbly 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 components 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 gear...

Page 30: ...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 ...

Page 31: ...m the vehicle 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 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 310 0510 0610 Features 310...

Page 32: ...310 0510 IHT 30 310 0710 EXPLODED VIEW ...

Page 33: ...6 Washer Thrust 59 x 79 x 04 57 20W 50 Oil 58 Brake Yoke Kit 59 Disk Brake 60 Brake Puck 61 Puck Plate 62 Brake Actuating Pin 63 Bolt Hex Head 1 4 20 x 2 w patch 65 Spacer 66 Spring Brake Arm Bias 68 Arm Brake 69 Nut Castle 5 16 24 70 Cotter Pin 3 32 X 3 4 71 Compression Spring Brake Anti Drag 72 Washer Flat 51 x 1 00 x 03 73 Washer Flat 34 x 88 x 06 74 Oil Seal 625 X 1 0 X 25 75 Check Plug Assy 0...

Page 34: ...310 0510 IHT 32 310 0610 EXPLODED VIEW ...

Page 35: ...ring Block 56 Washer Thrust 59 x 79 x 04 57 20W 50 Oil 58 Brake Yoke Kit Yoke Brake Bolt Sq Hd 5 16 24 Ribbed 59 Disk Brake 60 Brake Puck 61 Puck Plate 62 Brake Actuating Pin 63 Bolt Hex Head 1 4 20 x 2 w patch 64 Bolt Hex Head 1 4 20 x 1 w patch 65 Spacer 26 x 57 x 87 66 Spring Brake Arm Bias 68 Arm Brake 69 Nut Castle 5 16 24 70 Cotter Pin 3 32 X 3 4 71 Compression Spring Brake Anti Drag 72 Wash...

Page 36: ...310 0510 IHT 34 310 0510 EXPLODED VIEW 6 SEALANT 57 20W 50 OIL 127 SEAL O RING KIT ...

Page 37: ...3 Retaining Ring 55 Spring Helical Compression 56 Washer Thrust 59 x 79 x 04 57 20W 50 Oil 58 Brake Yoke 59 Rotor Brake 60 Brake Puck 61 Puck Plate 62 Brake Actuating Pin 63 Bolt Hex Hd 1 4 20 x 2 w patch 65 Spacer 66 Spring Brake Arm Bias 68 Arm Brake 69 Nut Castle 5 16 24 70 Cotter Pin 3 32 x 3 4 71 Compression Spring Brake Anti Drag 72 Washer HT 51 x 1 0 x 03 73 Flat Washer 34 x 88 x 06 74 Oil ...

Page 38: ...hing 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 f...

Page 39: ... 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 ...

Page 40: ...310 0510 IHT 38 2008 HYDRO GEAR Printed in U S A Rev P2 ...