Hydro-Gear 310 2400, 310 2600 Integrated Zero-Turn Transaxle Service and Repair Manual
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
310-2400/2600
Integrated Zero-Turn Transaxle
Service and Repair Manual
BLN-51134
December 2008
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
Table of Contents
Section Page
Foreword ........................................................................................................................................1
Section 1 Description and Operation...........................................................................................2
Introduction ...............................................................................................................................................................2
Description ..................................................................................................................................................2
Hydraulic
Flow...........................................................................................................................................................4
External
Features 310-2600R...................................................................................................................................7
Technical
Identification.................................................................................................................................................8
Section 2 Safety.............................................................................................................................9
Safety ................................................................................................................................................................9
Work
Servicing Safety ........................................................................................................................................................9
Section 3 Troubleshooting ......................................................................................................... 10
Section 4 Service and Maintenance ........................................................................................... 11
Maintenance .............................................................................................................................................11
Service Maintenance Procedures ....................................................................................................................11
Fluids.......................................................................................................................................................................12
Return to Neutral Setting.........................................................................................................................................14
Brake
Pack Adjustment ........................................................................................................................................15
Section 5 Repair........................................................................................................................... 16
How To Use This Section........................................................................................................................................16
Instructions ................................................................................................................................................16
Transaxle
Disassembly ...............................................................................................................................................16
Tools
Cover..............................................................................................................................................................18
Brakes ............................................................................................................................................................... 19-20
Shaft
Axle
Housing and Filter .................................................................................................................................. 24-25
Motor & Bevel Gear .......................................................................................................................................26
Center Section, Cylinder Blocks and Bypass.................................................................................................... 27-28
Input Shaft & Trunnion Arm .............................................................................................................................. 29-30
Transaxle
Assembly After a Complete Teardown ...................................................................................................................31
Sealant Application ..................................................................................................................... 32
Parts List .................................................................................................................................34-37
Glossary of Terms ..................................................................................................................38-39
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FOREWORD
Headquartered in Sullivan, Illinois, Hydro-
Gear
®
is a world leader in the design, manufacture, and service of quality hydrostatic transaxles for the lawn and garden industry.
The mission of our company is to be recognized by our customers and the industry as a world-class supplier and the quality leader in everything we do. the latest information available. All repair procedures illustrated in this guide are suggested, but preferred methods of repair.
Some repair procedures require that the IZT be removed from the vehicle.
This Service and Repair Manual is designed to provide information useful in servicing the
Hydro-Gear 310-2400, referred to as the
Integrated Zero Turn (IZT
®
), and 310-2600
Charged IZT.
Also included is a glossary of terms that are frequently used throughout the industry and in
Hydro-Gear service publications. Understanding terminology is very important!
It is necessary, and good shop practice, that your service area be equipped with proper tools and the mechanics to be supplied with
This is not a certification, test or study guide for a certification test. If a technician is interested in certification they should contact an agent representing the ESA (Engine Service
Association) (610) 363-3844 or their Hydro-
Gear Distributor. Many distributors will be hosting certification testing. These study guides will cover most of the products and manufacturers in our industry.
For more information about Hydro-Gear or our products, please contact your Central Service
Distributor, or call our Customer Service
Department at (217) 728-2581.
310-2400/2600 IZT
®
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1
2
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
SECTION 1. DESCRIPTION AND OPERATION
INTRODUCTION
The purpose of this manual is to provide information useful in servicing the Hydro-Gear
®
Integrated Zero Turn (IZT
®
) transaxle. This manual includes the IZT’s general description, hydraulic schematic, technical specifications, servicing and troubleshooting procedures.
The transaxle normally will not require servicing during the life of the vehicle in which it is installed. Should other servicing be required, the exterior of the transaxle will need to be thoroughly cleaned before beginning most procedures.
GENERAL DESCRIPTION
The 310-2400/2600 is a self contained unit designed for the transfer and control of power. It provides an infinitely variable speed range between zero and maximum in both forward and reverse modes of operation.
This transaxle uses a variable displacement pump with a maximum displacement of 10cc per revolution, and motor with a fixed displacement of 21cc per revolution. The variable displacement pump features a cradle mounted swashplate with a direct-proportional displacement control. Reversing the direction of the swashplate reverses the flow of oil from the pump and thus reverses the direction of the motor output rotation.
The pump and motor are of the axial piston design and utilize spherical nosed pistons which are held against a thrust race by internal compression springs.
The 310-2400/2600 has a self contained fluid supply and an internal filter. The 310-2400 fluid is forced through the filter by a positive
“head” on the fluid in the housing/expansion tank with an assist by the negative pressure created in the pump pistons as they operate.
The 310-2600 fluid is drawn through the internal reservoir and feeds the fixed displacement gerotor charge pump. Excess fluid in the charge circuit is discharged over the charge relief valve and dumps back to case.
The check valves in the 310-2400/2600 center section are used to control the makeup flow of the fluid to the low pressure side of the loop.
WARNING
Actuating the bypass will result in the loss of hydrostatic braking capacity.
The machine must be stationary on a level surface and in neutral when actuating the bypass.
A bypass is utilized in the 310-2400/2600 to permit moving the vehicle for a short distance at a maximum of 2 m.p.h. (3.2 Km/h) without starting the engine. The 310-2400/2600 is configured for both floating disc and cog style parking brakes. www.mymowerparts.com
310-2400/2600 IZT
®
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
310-2400
or or or
310-2600
or or or
310-2400/2600 IZT
®
Figure 1. 310-2400/2600 Hydraulic Flow Schematics
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3
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
310-2400
CYLINDER
BLOCK
ASSEMBLY
INPUT
SHAFT
VARIABLE
SWASHPLATE
VARIABLE
DISPLACEMENT
10cc PUMP
CHECK VALVE
BYPASS
ACTUATOR
CYLINDER BLOCK
ASSEMBLY
FIXED
SWASHPLATE
MOTOR
SHAFT
FIXED
DISPLACEMENT
21cc MOTOR
CHECK VALVE
TRANSAXLE
HOUSING
RESERVOIR
FILTER
4
310-2600
CYLINDER
BLOCK
ASSEMBLY
INPUT
SHAFT
VARIABLE
SWASHPLATE
VARIABLE
DISPLACEMENT
10cc PUMP
CHARGE
PUMP
CHECK VALVE
BYPASS
ACTUATOR
CYLINDER BLOCK
ASSEMBLY
FIXED
SWASHPLATE
MOTOR
SHAFT
FIXED
DISPLACEMENT
21cc MOTOR
CHECK VALVE
TRANSAXLE
HOUSING
RESERVOIR
FILTER
Figure 2. 310-2400 /2600Hydraulic Flow Illustration
310-2400/2600 IZT
®
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HYDRAULIC SCHEMATIC
Figure 2 provides an illustration of the hydraulic oil circuits. The oil supply for the hydraulic system of the 310-2400 IZT
®
and charged 310-
2600 IZT is also utilized for lubricating the components of the final drive assembly.
The input shaft and pump cylinder block are turned in one direction only by the engine/drive belt/pulley combination. Output of the oil flow is controlled by the direction and amount that the variable swashplate is angled. As the pump pistons compress they force the oil to flow through one of two passageways (forward or reverse) in the center section to the motor cylinder block and motor shaft. Since the motor has a fixed displacement angle it is forced to turn with the flow of oil. As the angle of the pump swashplate is increased the amount of oil being pumped will increase and cause a higher speed output of the motor. Reversing the angle of the swashplate will reverse the direction of oil flow.
During the operation of the transaxle, fluid is
“lost” from the hydraulic loop through leak paths designed into the product for lubrication purposes (around pistons, under the rotating cylinder blocks, etc.). This “lost” fluid returns to the transaxle housing, then is pulled back into one of the check valves depending upon the direction of vehicle operation. All of this oil must pass through an internal filter.
The motor cylinder block mounts onto a splined motor shaft which drives the gear train.
A charge pump is included on the IZT to supply this makeup flow. The make up flow is controlled (or directed) by the check valves.
Each check valve will either be held opened or closed (depending upon the direction of vehicle operation) by the system operating pressure (closed) or by charge pressure
(open) from the charge pump.
The charge pump maintains a continuous flow of oil as long as the input shaft is turning. All of the oil being pulled into the charge pump first must pass through an internal filter. Any oil not needed by the transmission for make up flow is discharged through the charge relief valve.
The charge relief valve maintains the charge pressure at no more than 40 PSI (2.76 bar).
The bypass feature in the 310-2600 has a mechanical lever which lifts the motor block off of the center section running surface, allowing any oil flowing from the pump block to be discharged into the housing without turning the motor.
Oil is forced through the filter by low inlet pressure only on the 310-2400, but is pulled by a charge pump circuit on the 310-2600.
310-2400/2600 IZT
®
5
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EXTERNAL FEATURES 310-2400L
Back Cover
Back Cover
Axle Shaft
Disc Brake Assembly
Hub
Assembly
Fill Port
Input Shaft
Bypass
Actuator
6
Cog Brake Assembly
Seal Plug
Lower Cover
Control Arm
Assembly www.mymowerparts.com
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®
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EXTERNAL FEATURES 310-2600R
Filter
Charge Cover
Charge Cover
Back Cover
Back Cover
Axle Shaft
Bypass
Bypass
Charge Cover
Input Shaft
Fill Port
Filter
Hub
Assembly
Oil Drain
Lower Cover
Charge Cover
Seal Plug
Filter
Control Arm
Assembly
Charge Cover
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®
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Cog Brake Assembly
“Only”
7
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
TECHNICAL SPECIFICATIONS
310-2400
Overall Transaxle Reduction
19.2:1
Input Speeds
Maximum: 3000 RPM
Minimum: 1800 RPM
Tire Diameter
18 in maximum; 45.7cm with 325 lbs; 147.4 kg maximum weight on tires
Axle Shaft Options
Type: Keyed / Double “D”
Diameter: 0.984 inch; 25.0 mm
Type: Flanged
Diameter: Hub
Brake Type
Disc, Parking
Cog, Parking
Weight of Unit
30 lb; 13.6 kg
310-2600
Overall Transaxle Reduction
19.2:1
Input Speeds
Maximum: 3400 RPM
Minimum: 1800 RPM
Tire Diameter
20 in maximum; 45.7cm with 325 lbs; 147.4 kg maximum weight on tires
Axle Shaft Options
Type: Keyed / Double “D”
Diameter: 0.984 inch; 25.0 mm
Type: Flanged
Diameter: Hub
Brake Type
Cog, Parking
Weight of Unit
31 lb; 14 kg
Table 1. 310-2400/2600 Technical Specifications
PRODUCT IDENTIFICATION
The model and configuration of the 310-2400/2600 IZT
® in Figure 3.
can be determined from the label shown
7 8 8 7 8 6
I II IIII IIII III III I II IIII
3
S e ria l N u m b e r
(uniq ue nu m be r fo r that m odel - fo r that day )
8
Figure 3. 310-2600 Configuration Label
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310-2400/2600 IZT
®
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SECTION 2. SAFETY
This symbol points out important safety instructions which, if not followed, could endanger the personal safety and/or property of yourself and others. Read and follow all instructions in this manual before attempting maintenance on your transaxle. When you see this symbol - HEED ITS WARNING.
WARNING
POTENTIAL FOR SERIOUS INJURY
Certain safety precautions must be observed while servicing or repairing the 310-2400 IZT
®
.
This section addresses some of these precautions but must not be considered an allinclusive source on safety information. This section is to be used in conjunction with all other safety material which may apply, such as:
1) Other manuals pertaining to this machine,
2) Local and shop safety rules and codes,
3) Governmental safety laws and regulations. nel to service or repair the equipment.
Inattention to proper safety, operation, or maintenance procedures could result in personal injury, or damage to the equipment. Before servicing or repairing the
310-2400 IZT, fully read and understand the safety precautions described in this section.
PERSONAL SAFETY
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-
Wear appropriate clothing. Loose or hanging clothing or jewelry can be hazardous. Use the appropriate safety equipment, such as eye and hearing protection, and safety-toe and slipproof shoes.
Never use compressed air to clean debris from yourself or your clothing.
TOOL SAFETY
Use the proper tools and equipment for the task.
Inspect each tool before use and replace any tool that may be damaged or defective.
WORK AREA SAFETY
Keep the work area neat and orderly. Be sure it is well lit, that extra tools are put away, trash and refuse are in the proper containers, and dirt or debris have been removed from the working areas of the machine.
The floor should be clean and dry, and all extension cords or similar trip hazards should be removed.
SERVICING SAFETY
Certain procedures may require the vehicle to be disabled in order to prevent possible injury to the servicing technician and/or bystanders.
The loss of hydrostatic drive line power may result in the loss of hydrostatic braking capability. Proper brake maintenance is very important should this condition develop.
Some cleaning solvents are flammable. Use only approved cleaning materials. Do not use explosive or flammable liquids to clean the equipment.
To avoid possible fire do not use cleaning solvents in an area where a source of ignition may be present.
Discard used cleaning material in the appropriate containers.
310-2400/2600 IZT
®
9
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SECTION 3. TROUBLESHOOTING
WARNING
Do not attempt any servicing or adjustments with the engine running.
Use extreme caution while inspecting the drive belt assembly, and all vehicle linkage!
Follow all safety procedures outlined in the vehicle owner’s manual!
In many cases problems with the 310-
2400/2600 IZT are not related to a defective transaxle, but are caused by slipping drive belts, partially engaged bypass valves, and loose or damaged control linkages. Be sure to perform all operational checks and adjustments outlined in Section 4, Service and Maintenance before assuming the unit is malfunctioning. Table 2 below provides a troubleshooting check list to help determine the cause of operational problems.
10
Table 2. 310-2400 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 11
Repair or replace drive belt or pulley, Page 11
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
Debris buildup around transaxle
Brake setting incorrect
Cooling fan damaged
Oil level low or contaminated oil
Excessive loading
Air trapped in hydraulic system
UNIT IS NOISY
Oil level low or contaminated oil
Excessive loading
Brake setting incorrect
Loose parts
Bypass assembly sticking
Air trapped in hydraulic system
Filter clogged with debris
Engine speed low
Control linkage bent or out of adjustment
Brake setting incorrect
Drive belt slipping or pulley damaged
Oil level low or contaminated oil
Excessive loading
Bypass assembly sticking
Air trapped in hydraulic system
Filter clogged with debris
Fill to proper level or change oil, Page 12
Reduce vehicle loading, Page 11
Adjust brake to proper setting, Page 15
Repair or replace loose parts
Repair or replace valve or linkage
Purge hydraulic system, Page 13
Replace filter, Page 12
UNIT HAS NO/LOW POWER
Adjust to correct setting
Repair or replace linkage, Page 11
Adjust brake to proper setting, Page 15
Repair or replace drive belt or pulley, Page 11
Fill to proper level or change oil, Page 12
Reduce vehicle loading, Page 11
Repair or replace valve or linkage
Purge hydraulic system, Page 13
Replace filter, Page 12
UNIT OPERATING HOT
Clean off debris, Page 11
Adjust brake to proper setting, Page 15
Repair or replace cooling fan
Fill to proper level or change oil, Page 12
Reduce vehicle loading, Page 11
Purge hydraulic system, Page 13
Damaged seals, housing, or gaskets
Air trapped in hydraulic system
TRANSAXLE LEAKS OIL
Replace damaged component
Purge hydraulic system, Page 13
310-2400/2600 IZT
®
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SECTION 4. SERVICE AND MAINTENANCE
NOTE: Any servicing dealer attempting a warranty repair must have prior approval before conducting maintenance of a Hydro-Gear product unless the servicing dealer is a current Authorized Hydro-Gear Service Center.
EXTERNAL MAINTENANCE
Regular external maintenance of the 310-2400
IZT
®
should include the following:
1. Check the vehicle operator’s manual for the recommended load ratings. Insure the current application does not exceed
load rating.
2. Check oil level and quality in accordance with Figure 4 Page 12.
3. Inspect the vehicle drive belt, idler pulley
(s), and idler spring(s). Insure that no belt slippage can occur. Slippage can cause low input speed to the transmission.
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 310-2400/2600 is mounted on the vehicle. Any repair procedures as mentioned in the repair section of this manual must be performed after the unit has been removed from the vehicle.
310-2400/2600 IZT
®
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11
FLUIDS
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
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 (9 cSt) at 230°F (110° C) and an API classification of SL is recommended. A SAE
20W-50 engine oil has been selected for use by the factory and is recommended for normal operating temperatures.
FLUID VOLUME AND LEVEL
Fluid volume information is provided in Table 3.
Certain situations may require additional fluid to be added or even replaced. Refer to Figure 4 for the proper fill port location.
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 13.
FLUID CHANGE
The 310-2400 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 performance problems.
310-2600 charged IZT
®
oil change requirements may vary with usage. But, regular maintenance filter and oil change at 200 hour intervals is recommended.
CAUTION
Do not overfill.
If you overfill the transaxle while the unit is “cold”, it may overflow as it reaches normal operating temperatures. The oil level should not be above the manufacturer’s suggestions outlined in this manual. This will allow the space needed for the oil to expand as it warms up.
It is essential that the unit exterior be free of debris prior to fluid maintenance.
Remove the oil drain plug (87) to facilitate oil change. Refer to figure 14. Page 25. To reinstall oil drain plug reference table 5. for proper torque.
IMPORTANT: When tightening the filter insure proper torque value 20-50 in lbs (2-6
Nm) is applied. Filter is plastic. Excessive torque will damage filter.
Table 3. Fluid Volumes for the 310-2400/2600 IZT
Fluid Description Volume
20W-50 engine oil 79 fl. oz. (2336 ml.)
FILL PORT
1⅞" (48.0 mm)
OIL
LEVEL
12
Figure 4. 310-2400/2600 Fluid Level and Fill Port
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®
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PURGING PROCEDURES
Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that it be 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 compression and expansion rate is higher than that of the oil normally 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
12, 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 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 may 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.
310-2400/2600 IZT
®
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13
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RETURN TO NEUTRAL SETTING
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 technician and/or bystanders, insure the vehicle is properly secured.
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.
The return to neutral mechanism on the transmission is designed to set the directional control into a neutral position when the operator removes their hands from the control. Follow the procedures below to properly adjust the return to neutral mechanism 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 linkage control and the transaxle return arm.
2. Remove the Original Equipment Manufacturer’s (OEM’s) control linkage at the return arm. Refer to Figure 5.
3. Start the engine and increase the throttle to full engine speed.
4. Check for axle 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 adjust the OEM linkage to the return arm 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 lock down screw until the return arm can be rotated.
Refer to Figure 5 below to make adjustment. In general, rotate the return arm in the direction opposite of axle rotation. If the axle is rotating in the “B” direction, rotate the return arm in the “A” direction, and viceversa. Continue until axle rotation stops.
Tighten the lock down screw. Refer to Table
5 Required Torque Values, Page 17. 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.
AXLE ROTATION “B”
AXLE ROTATION “A”
LOCK DOWN SCREW
RETURN ARM
AXL
E R
OTA
TIO
N “A
”
14
AXLE R
OTAT
ION “B
”
Figure 5. Return to Neutral Control
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®
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BRAKE MAINTENANCE
COG BRAKE MAINTENANCE
1. Check the brake arm teeth for damage or excessive wear. Replace if necessary.
2. Check for excessive looseness at brake arm pivot point.
DISC BRAKE MAINTENANCE
(310-2400 Only)
1. Remove the brake return spring, and then the cotter pin securing the brake castle nut.
2. Insert a 0.020" (0.5 mm) feeler gage between the brake rotor and outer brake friction stator, and then set the brake by 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.
FRICTION PACK ADJUSTMENT
The friction pack dampens or holds the operator 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 assembly of the nut to 100 in-lbs (11 Nm) torque. The friction pack nut is then backed off per vehicle manufacturer’s specifications.
FRICTION PACK
ADJUSTING NUT
BRAKE ARM TEETH
PIVOT
CONTROL ARM
Figure 7. Friction Pack
COG PARKING BRAKE
BRAKE SETTING LOCATION
DISC PARKING BRAKE
Figure 6. Brake Options
310-2400/2600 IZT
®
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15
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
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 34,35,36 and 37 for part names and descriptions. A complete exploded view and item list of the transaxle is provided at the end of this section.
It is necessary to remove the 310-2400/2600 from the vehicle before performing the repair procedures presented in this section. Use the following procedure to prepare the unit for removal from the vehicle.
1. With the vehicle wheels on the ground, loosen the ¾-16 hex nut (108, Figure 12)
Page 23, if so equipped. Use an air impact wrench and a 1-1/8” socket to loosen the nut.
Many of the parts and subassemblies of this transaxle can be removed and serviced independently 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.
2. Lift the vehicle wheels off the ground and remove the nut completely.
3. Remove the wheel from the hub.
GENERAL INSTRUCTIONS
4. Using a wheel or gear puller, remove the hub from the shaft.
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.
CAUTION
USE CARE IN REMOVING THE HUB TO
PREVENT CRACKING.
LIMITED DISASSEMBLY
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, Orings, 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).
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 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 summary of the assembly procedures, in the order in which they should occur, is given on page 31.
TRANSAXLE REMOVAL
16
310-2400/2600 IZT
®
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TOOLS AND TORQUES
Miscellaneous
310-2400 Service & Repair Manual
Flat Blade Screw Driver
Torque Wrench
Air Impact Wrench
Rubber Mallet
Pliers
Needle Nose
Large External Snap Ring
Small External Snap Ring
Large Internal Snap Ring
Table 4. Required Tools
Sockets
3/8"
1/2"
7/16"
9/16"
E-8 Torx Head
Wrenches
1/2"
5 mm Allen
3/8” Allen
1/4” Allen
Operation
Wheel Hub Nut
Fan/Pulley Nut
Back Cover Screws
Friction Pack Stud
Control Arm Nut
Control Bolt
Brake Yolk Screw
U.S. Torque
200-295 ft-lbs
360-520 in-lbs
110-150 in-lbs
50-120 in-lbs
180-240 in-lbs
192-252 in-lbs
80-120 in-lbs
Cog Brake Arm Screw 110-150 in-lbs
Check Plug Assembly 200-360 in-lbs
Lower Housing Screw 110-150 in-lbs
Center Section Screw 525-700 in-lbs
Lock Down Screw
Oil Drain Plug
210-270 in-lbs
180-240 in-lbs
Filter 20-50 in-lbs
Charge Cover Screws 87-100 in-lbs
Table 5. Required Torque Values
Metric Torque
271-400 Nm
41-59 Nm
12-17 Nm
6-14 Nm
20-27 Nm
22-28 Nm
9-14 Nm
12-17 Nm
23-41 Nm
12-17 Nm
59-79 Nm
24-30 Nm
20-27 Nm
2-6 Nm
9-11 Nm
123
45
50
44
208
87
46
86
Item
108
49
50
36
35
76/121
123/211
Description
Nut, Hex 3/4-16
Nut, Hex Lock 1/2-20
Screw, 1/4-20
Stud, 5/16-24
Nut, 5/16-24
Nut/Bolt, 5/16-18
Screw, 1/4-28
Screw, Hex 1/4-20
Check Plug Assembly
Screw, 1/4-20
Screw, 3/8-24
Screw, 5/16-24 (Lock-Down)
Plug , 9/16-18 (Metal)
Assembly, Filter
SHCS M6 X 20
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BACK COVER
Refer to Figure 8.
ASSEMBLY
DISASSEMBLY
1. Apply sealant to the back cover (1). Refer to page 29.
1. Remove the eight screws (50) from the back cover (13), and discard. 2. Place the back cover (13) onto the main housing assembly (1).
2. Remove the back cover (13). Take care not to damage the casting surfaces.
3. Clean off the sealant from the mating surfaces of the back cover (13) and the main housing assembly (1).
3. Install the eight replacement screws (50) to secure the back cover (13) to the main housing assembly (1). Tighten the eight screws (50) to the torque value listed in
Table 5.
INSPECTION
1. Inspect the back cover (13) for excessive wear or damage.
50
13
18
1
Figure 8. Back Cover Assembly
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BRAKES
(Cog Brake)
Refer to Figure 9.
DISASSEMBLY
1. Remove the external retaining ring (63).
2. Remove the brake bolt (123), brake arm
(70) and brake disc (73). Note the orienta-
tion of the hub on the brake disc.
INSPECTION
1. Inspect the brake disc (73) for damaged splines or gear teeth.
2. Inspect the brake arm (70) for damaged teeth.
ASSEMBLY
1. Insert the brake shaft (55) into the main housing (1). Slide the brake disc (73) onto the brake shaft (55). Note the orientation of
the brake disc. The hub on the brake disc should face inward on R.H. units and outward on L.H. units.
2. Install the brake arm (70) and brake bolt
(123) onto the main housing (1). Tighten the brake bolt (123) to the torque value listed in Table 5.
3. Install an external retaining ring (63) onto the brake shaft (55).
55
63
73
1
123
70
Figure 9. Cog Brake Assembly
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BRAKES
(Disc Brake 310-2400 Only)
ASSEMBLY
Refer to Figure 10.
DISASSEMBLY
1. Slide the stators (127) and rotor (73) onto the brake shaft (55, Figure 11). Pay close attention to the stack up of the stators and rotor.
1. Remove the cotter pin (128) and slotted hex nut (133). Discard the cotter pin.
2. Remove the washer (19), brake arm (70), compression spring (130) and brake actuating pins (129).
2. Install the brake yoke (131) with the three brake yoke screws (123) onto the main housing (1). Refer to Table 5 for the required torque.
3. Remove the three brake yoke screws (123).
Remove the brake yoke (131).
3. Install the brake actuating pins (129) and compression spring (130) onto the brake yoke (131).
4. Remove the stators (127) and rotor (73).
INSPECTION
1. Inspect the brake components for excessive wear. Replace if necessary.
4. Install the brake arm (70), washer (19) and slotted hex nut (133) onto the brake yoke
(131). Do not tighten the slotted hex nut
(133) at this time.
5. Insert a .020" (0.5 mm) feeler gage between the brake rotor (73) and outer stator (127).
Adjust the brake by tightening or loosening the slotted hex nut (133).
6. Install a new cotter pin (128) to secure the slotted hex nut (133).
20
127
127
130
70
129
19
73
133
128
131
123
Figure 10. Disc Brake Assembly
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BRAKE SHAFT & BEVEL GEAR
Refer to Figure 11.
INSPECTION
DISASSEMBLY
1. Remove the back cover. See page 18.
1. Inspect the brake shaft (55), ball bearing
(26) and bevel gear (52) for wear or damage.
2. Remove the brake. See pages 19-20.
ASSEMBLY
3. Remove the brake shaft lip seals (58) and retaining rings (126). Discard the lip seals
(58).
1. Insert the brake shaft (55) and ball bearing
(26) into the main housing (1) allowing the brake shaft (55) to pass through the 19 tooth bevel gear (52).
4. Remove the retaining ring (67) from the outside of the ball bearing (26).
2. Install the retaining ring (67).
5. Remove the brake shaft (55) and ball bearing (26) from the 19 tooth bevel gear
(52). It may be necessary to tap lightly on
the brake shaft (55) to remove the bearing
(26).
3. Install the brake shaft lip seals (58) and retaining rings (126).
4. Install the brake. See pages 19-20.
5. Install the back cover. See page 18.
6. Remove the 19 tooth bevel gear (52).
55
67
126
26
58
58
310-2400/2600 IZT
®
126
52
1
Figure 11. Brake Shaft & Bevel Gear Assembly
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
AXLE SHAFT & SPUR GEAR
Refer to Figure 12.
ASSEMBLY
DISASSEMBLY
1. Remove the back cover. See page 18.
1. Place the spur gear (53) and axle bushings
(81&82), per noted orientation, into the main housing (1).
2. Remove the brake. See page 19-20.
3. Remove the brake shaft and bevel gears.
See page 21.
4. Remove the hub assembly (107), if not already removed.
Note: The orientation of the hub and
axle to the main housing is critical in reassembly.
5. Remove the retaining ring (68) from the outside of the axle shaft seal (66).
2. Insert the axle shaft bearing (64) and axle shaft (56) into the main housing (1).
(A clean screwdriver may be used to help align the gear and bushings during installation).
3. Place the axle retaining ring (62) onto the end of the axle shaft (56).
4. Using a rubber or plastic mallet, lightly tap a new side seal plug (60) into the main housing (1). Install the seal plug retaining ring (68).
6. Remove the axle shaft seal (66) and discard.
5. Slide the axle shaft bearing (65) onto the hub end of the axle shaft (56).
7. Remove the retaining ring (68) from the outside of the side seal plug (60).
8. Remove the side seal plug (60) by lightly tapping on the end of the axle shaft (56) with a plastic or rubber mallet. Discard the side seal plug (60).
6. Slide the axle seal (66) onto the axle shaft
(56). Remember to protect the seal (66) during installation by covering the axle shaft (56) with cellophane. Remove the cellophane once the seal (66) is installed.
7. Install the retaining ring (68).
9. Remove the axle shaft retaining ring (62) from the axle shaft (56).
8. Install the hub assembly (107) and nut
(108) with the bolt threads facing away from the transaxle.
10. Remove the axle shaft (56) from the main housing assembly (1). Remove the ball bearings (64 & 65) from the axle shaft
(56). Note the orientation of the axle shaft bushings (81 & 82). This is important for reassembly. Remove the two axle shaft bushings (81 & 82) and spur gear (53) from the inside of the main housing (1).
9. Install the brake shaft and bevel gear. See page 21.
10. Install the brake. See pages 19-20.
11. Install the back cover. See page 18.
INSPECTION
1. Inspect the ball bearings (64 & 65) and axle shaft (56) for wear or damage.
2. Inspect the spur gear (53) for wear or damage.
22
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AXLE SHAFT & SPUR GEAR
82
53
81
65
68
56
66
108
107
Figure 12. Axle Shaft & Spur Gear Assembly
1
62
68
64
60
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
LOWER HOUSING & FILTER
Refer to Figure 13.
DISASSEMBLY 310-2400
1. Remove the ten screws (50) holding the lower housing (2) to the main housing (1), and discard.
ASSEMBLY
1. Install a new filter (46).
2. Apply sealant to the lower housing (2) where the lower housing (2) mates with the main housing (1). Refer to page 29.
2. Remove the lower housing (2) and old sealant. Take care not to damage the casting surfaces.
3. Remove and discard the internal filter (46).
3. Place the lower housing (2) on the main housing (1).
4. Install the ten replacement screws (50) that hold the lower housing (2) to the main housing (1).
INSPECTION
1. Inspect the lower housing (2) for excessive wear or damage.
5. Torque the ten screws (50) to the value listed in Table 5.
24
1
46
2
50
Figure 13. Lower Housing & Filter 310-2400
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LOWER HOUSING & FILTER
Refer to Figure 14.
DISASSEMBLY 310-2600
1. Place an orientation mark on the charge cover. wear or damage.
2. Inspect charge cover (85) and gerotor (84) for excessive wear or damage.
ASSEMBLY
2. Remove the two screws (86), charge cover
(85), o-ring (83) and gerotor assembly (84).
1. Apply sealant to the lower housing (2) where it mates with the main housing (1).
Refer to page 29.
3. Remove filter assembly (46).
4. Remove the ten screws (50) holding the lower housing (2) to the main housing (1), and discard.
5. Remove the lower housing (2) and old sealant. Take care not to damage the casting surfaces.
2. Place the lower housing (2) on the main housing (1).
3. Install the ten replacement screws (50) that hold the lower housing (2) to the main housing (1).
4. Torque the ten screws (50) to the value listed in Table 5.
INSPECTION
5. Install a new filter (46).
1. Inspect the lower housing (2) for excessive
IMPORTANT: When tightening the filter insure proper torque value 20-50 in lbs (2-6
Nm) is applied. Filter is plastic. Excessive
torque will damage filter.
1
2
50
87
46
84
86
Figure 14. Lower Housing & Filter 310-2600
310-2400/2600 IZT
®
83
85
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
MOTOR SHAFT & BEVEL GEAR
Refer to Figure 15.
ASSEMBLY
DISASSEMBLY
1. Remove the back cover. See page 18.
1. Install the motor shaft (54), bearing assembly (26) and wire retaining ring (27). Note:
The splines must be aligned when in-
serting the motor shaft (54).
2. Remove the brake. See pages 19 & 20.
3. Remove the brake shaft & bevel gear.
See page 21.
2. Install the 14 tooth bevel gear (51) on the end of the motor shaft (54).
4. Remove the axle shaft & spur gear.
See pages 22 & 23.
3. Install the axle shaft and spur gear. See pages 22 and 23.
5. Remove the 14 tooth bevel gear (51) from the motor shaft (54).
4. Install the brake shaft and bevel gear. See page 21.
5. Install the brake. See pages 19 and 20.
6. Remove the motor shaft (54), wire retaining ring (27) and bearing assembly (26) from the main housing (1). Note: The bearing
(26) does not fit flush with the housing.
This is important for reassembly.
6. Install the back cover. See page 18.
INSPECTION
1. Inspect the gear (51), shaft (54) and bearing (26) for wear or damage.
26
1
27
51
26
54
Figure 15. Motor Shaft & Bevel Gear Assembly
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CENTER SECTION, CYLINDER BLOCKS AND BYPASS
Refer to Figure 16.
INSPECTION
DISASSEMBLY
1. Check the pistons in the motor and pump blocks for free movement.
1. Remove the back cover. See page 18.
2. Remove the brake assembly. See pages
19 and 20.
2. Remove and inspect the pistons, springs and seats for wear or damage.
3. Remove the brake shaft and bevel gear.
See page 21.
3. Inspect the piston bores in the cylinder blocks for wear or damage.
4. Remove the axle shaft and spur gear. See pages 22 and 23.
5. Remove the lower housing and filter. See page 24 and 25.
4. Check the running surface of the motor and pump cylinder blocks for damage. This surface must be smooth in the three sealing areas. Reassemble the motor and pump cylinder block assemblies and set aside.
6. Remove the motor shaft and bevel gear.
See page 26.
5. Inspect the bushing in the center section and the by-pass plate (38).
7. Remove the three screws (44) holding the center section (3) to the upper housing (1).
Lift to remove the center section (3) and motor cylinder block assembly (21). Remove the two pins (43).
6. Check the motor and pump cylinder block running surfaces on the center section (3).
This surface should be smooth. Drag a fingernail across it to detect scratches or smearing.
8. Remove the motor cylinder block assembly
(21).
7. Inspect the thrust bearing assemblies (11 and 25) for wear or damage.
9. Remove the motor block thrust bearing assembly (25). Note: The thick race is lo-
cated nearest to the pistons when as-
sembled properly.
10. Remove the pump block assembly (15).
ASSEMBLY
1. Install a new bypass lip seal (40). Install the bypass arm (41) and retaining ring (42) onto the bypass actuator (39).
2. Install the slot guide (30, Fig. 17).
11. Remove the pump block spring (14), washer (24) and swashplate assembly
(10).
12. Remove the thrust bearing assembly (11).
Note: The thick race is located nearest
to the pistons when assembled prop-
erly.
13. Remove the slot guide (30, Fig. 17).
3. Install the swashplate assembly (10)
(including the thrust bearing assembly).
Note: Install the thrust bearing assembly
(11) with the thick race towards the pis-
tons.
4. Actuate the trunnion arm (31) and swashplate (10) to verify free movement.
5. Install the pump block washer (24) and spring (14).
14. Remove the bypass arm retaining ring
(42), bypass arm (41) and bypass lip seal
(40). Discard the lip seal.
6. Install the pump block assembly (15).
7. Center the by-pass actuator (39) in the housing pocket.
310-2400/2600 IZT
®
27
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CENTER SECTION, CYLINDER BLOCKS AND BYPASS
8. Install the two pins (43).
9. Install the by-pass plate (38) into the center section (3). Install the center section (3) and motor cylinder block assembly (21).
10. Install the three screws (44) that hold the center section (3) in place.
11. Install the thrust bearing assembly (25).
Note: Install the thrust bearing assem-
bly with the thick race towards the pis-
tons.
12. Install the motor shaft and bevel gear. See page 26.
13. Install the filter and lower housing. See page 24 and 25.
14. Install the axle shaft and spur gear. See pages 22 and 23.
15. Install the brake shaft and bevel gear. See page 21.
16. Install the brake. See pages 19 and 20.
17. Install the back cover. See page 18.
42
41
40
28
1
31
39
10
11
24
38
43 14
15
25
3
21
43
44
Figure 16. Center Section, Cylinder Blocks and Bypass
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Refer to Figure 17.
ASSEMBLY
DISASSEMBLY
1. Install the trunnion arm (31) if removed and install a new trunnion seal (33).
1. Remove the back cover. See page 18.
2. Install the slot guide (30).
2. Remove the brakes. See pages 19 and 20.
3. Remove the brake shaft and bevel gear.
See page 21.
3. Install the input shaft (12), bearing assembly (8) and wire retaining ring (6), if removed.
4. Remove the axle shaft and spur gear. See pages 22 and 23.
4. Install the spacer (5).
5. Remove the lower housing and filter. See page 24 and 25.
5. Install a new input shaft lip seal (4). Remember to protect the seal during installation by covering the shaft with cellophane.
6. Remove the motor shaft and bevel gear.
See page 26.
6. Install the input shaft retaining ring (7).
7. Remove the center section and cylinder block assemblies. See pages 27 and 28.
7. Install the center section and cylinder block assemblies. See pages 27 and 28.
8. Remove the input shaft retaining ring (7).
8. Install the motor shaft and bevel gear. See page 26.
9. Remove and discard the lip seal (4).
10. Remove the spacer (5).
9. Install the lower housing and filter. See page 24 and 25.
11. Remove the input shaft (12) and bearing
(8).
10. Install the axle shaft and spur gear. See pages 22 and 23.
12. Remove the slot guide (30).
11. Install the brake shaft and bevel gear.
See page 21.
13. Rotate the trunnion arm (31) to check for free movement.
12. Install the brakes. See pages 19 and 20.
14. Remove the trunnion shaft seal (33) if necessary and remove the trunnion arm
(31).
13. Install the back cover. See page 17.
INSPECTION
1. Inspect the input shaft (12) and bearing (8) for wear or damage.
2. Inspect the slot guide (30).
3. Inspect the trunnion arm (31) for wear or damage.
4. Inspect the non-removable cradle bearings
(9) in the main housing (1) for excessive wear.
310-2400/2600 IZT
®
29
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
INPUT SHAFT & TRUNNION ARM
4
6
7
5
8
33
30
30
31
1
9
Note: Cradle bearings are nonremovable. Shown removed for illustration purposes only.
12
Standard
Figure 17. Input Shaft and Trunnion Arm Assembly
12
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TRANSAXLE INSTALLATION ASSEMBLY AFTER A COMPLETE
TEARDOWN
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.
If the unit has been torn down completely, the following summary identifies the assembly procedures necessary to completely assemble the unit. Each assembly procedure is located by a page reference.
2. Install the hub assembly (107, page 23) if not already done. Install the ¾-16 hex nut
(108, page 23).
3. With the vehicle raised, install the wheel on the hub, and snug the wheel lug nuts.
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 30.
1. Install the input shaft and trunnion arm. See page 29.
4. Lower the vehicle wheels to the ground and torque the ¾-16 hex nut to 200-295 ft.-lbs.
(271-400 Nm).
2. Install the center section, motor and pump cylinder blocks. See page 27.
5. Tighten the wheel lug nuts per the vehicle owner’s manual.
3. Install the motor shaft and bevel gear. See page 26.
4. Install the filter and lower housing. See pages 24 and 25.
5. Install the axle shaft and spur gear. See pages 22 and 23.
6. Install the brake shaft and bevel gear. See page 21.
7. Install the brake. See pages 19 and 20.
8. Install the back cover. See page 17.
9. Fill the transaxle with 79 fluid ounces
(2336 ml.) of new 20w50 motor oil. This should put the oil level approximately
1⅞" (48 mm) from the top of the housing.
This should be checked at the fill port.
10. Install the transaxle onto the vehicle.
11. Perform the purge procedures listed on page 13.
12. Perform the return to neutral procedure on page 14.
310-2400/2600 IZT
®
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
SEALANT APPLICATION
NOTE: Prior to applying the new sealant, the old sealant must be removed from all surfaces.
A small bead of the sealant around the outer part of the housing face will be sufficient. Use sparingly.
The illustrations below indicate the correct areas.
Sealant Path
Sealant Path
Back Cover Sealant Path 310-2400 Lower Housing Sealant Path
32
Sealant Path
310-2600 Lower Housing Sealant Path
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®
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
PRODUCTS AFFECTED:
All Hydro-Gear
®
IZT
®
models
(310-2400 Series)
Service Bulletin
SUBJECT:
Water Exclusion Kit
SB-51888
Rev. P
DESCRIPTION: It has been determined that on some IZT applications, water intrusion, resulting from unprotected exposure to the environment or high pressure washing is possible. This bulletin details the parts to be used in preventing the potential for water intrusion.
This is a preventative product improvement: Not intended for Hydro-Gear warranty reimbursement.
Water Exclusion Kit Part Number 70968 is used on models: 015606, 015618, 321-2400R, 322-2400R, 322-2400L, 335-2400L,
335-2400R, D-3725-02, D-3725-01, 01008192, 01008193, 130333, 130332, 015679, 015680.
Water Exclusion Kit Part Number 70969 is used on models: 100-7360,100-7361, 107605, 107606, 3600, 3600CB.
Water Exclusion Kit Part Number 70970 is used on models: 618-0437, 618-0438, 326-2400R, 326-2400L, 3601, 782862,
782854, 333-2400L, 333-2400R, 3601CB.
Water Exclusion Kit Part Number
70968
Water Exclusion Kit Part Number
70969
Water Exclusion Kit Part Number 70970
Breather Assy.
Fitting O Ring Assy.
Bypass Washer
Bypass Retaining Ring
Brake Cover
Breather Assy.
Bypass Washer
Bypass Retaining Ring
Brake Cover
Breather Assy.
Bypass Washer
Bypass Retaining
Ring
Brake Cover
Bypass Retaining Ring
Bypass Washer
Brake Cover
For more technical assistance contact your Hydro-Gear Central Service Distributor.
Part No. BLN-51888
DATE: APRIL 2003
310-2400/2600 IZT
®
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Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
310-2400 EXPLODED VIEW
34
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®
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
No. DESCRIPTION
Housing-Main
Housing,
Bearing
Lip
Bushing
2 Lower
3 Center Section Assembly Kit
Bypass
Check Plug Assembly
Center Section
Bushing
Seal
5 Spacer
6 Wire Retaining Ring
7 Retaining
8 Ball
Bearing
10 Variable
11
Bearing
Swashplate
Thrust Bearing 30 X 52 X 13
Shaft
13 Cover-Back
14 Spring,
15 10cc Cylinder Block Assy
10cc Cylinder Block
10cc Piston Spring
10cc Piston
19 Washer
21 21cc Cylinder Block Assy
21cc Cylinder Block
21cc Piston Spring
Piston Seat Washer
24
25
26 Ball
27
Washer, Block Thrust
Thrust Bearing 42 X 68 X 16
Wire Retaining Ring
30 Slot
Arm
33 Lip
34 RTN
35
Arm
Standard Control Arm
RTN Hex Lock Nut, 5/16-24 UNJF (Nylon Insert)
Standard Control Arm Nut
36 Stud-Long
Puck
38 Bypass
Actuator
40 Lip
41 Bypass
42 Retaining
43 Pin
44 Screw
46 Filter
49
50
51
52
53
Hex Lock Nut 1/2-20 (Nylon Insert)
Screw, 1/4-20 X .75 Long
14T Bevel Gear
19T Bevel Gear
53T Spur Gear
Shaft
55 Brake
56
58
60
62
Shaft, Axle 25mm X 14 (D,D)
Axle
Seal, Lip 17 X 40 X 7
Seal Plug - Side
Retaining Ring - Axle
63 Retaining
64
65
Kit
Bearing-Ball 20 X 47 X 14 (6204)
Bearing-Ball 20 X 47 X 12 (6205)
66 Seal
Ring-Axle
70 Arm,
71
Ring
Brake
RH, Brake Arm Service Assy
73
Arm
Clevis
Bushing 0.255 X 0.381 X 0.330
Hex Washer Head Screw, 1/4-20 X 7/8
Disc Brake Yoke Brake Rotor
Cog Brake Arm Brake Disc
Hex Nut 5/16-18 76
80 20W-50
Bushing
82 Axle Bushing
310-2400/2600 IZT
®
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310-2400 ITEMS LIST
No. DESCRIPTION
Plug
100 Sealant
Brake
Washer
Stator, Brake Friction
Cotter Pin 3/32 X 3/4
Brake Actuating Pin
Compression Spring Anti Drag
Yoke-Brake
107 Hub
Hub
Lug
108
110
Nut, Hex 3/4-18
Fitting O-Ring Assembly
Plastic Hose Fitting
O-Ring
111 Cap Vent Assembly
Valve
Vent
119 Spacer
120 Pulley,
121
122 Helical
123
126
127
128
129
130
Bolt 5/16-18 X 1-1/4
131 Kit,
Spring
Disc Brake Yoke Screw, 1/4-28 X 1.38 W/Patch
Cog Brake Arm Hex Washer Head Screw, 1/4-20 X 7/8
Ring Retaining
Stator, Brake Friction
Cotter Pin 3/32 X 3/4
Brake Actuating Pin
Compression Spring Brake Anti Drag
Yoke-Brake
133
Sq Hd Bolt 5/16-24 Ribbed
Yoke,
Slotted Hex Nut 5/16-24
134 Kit,
Seal, Lip 15 X35 X 7
Ring,
Seal, Lip 12 X 25 X 7
Seal, Lip 10 X 25 X 7
Ring, Retaining
Seal, Lip 17 X 40 X 7
Seal, Lip 1.85 X 32
Retaining
Ring, Retaining .440 External
Seal, Lip .98 X 1.85 X .276
135
136
Seal, Lip 17 X 40 X 5
Screw, 1/4-20 X .75 Long
Washer, .531 X 1.250 X .092 (Belleville)
Fan, 6”, 10 Blade
137 Kit,
Washer, .531 X 1.250 X .092 (Belleville)
Fan, 6”, 10 Blade
141
142
143 Cover
207 Spacer,
208
Hex Lock Nut 1/2-20 (Nylon Insert)
Pulley,
Washer, .34 x .88 x .03
Washer,
Brake
RTN
Screw, 5/16-24 X .75 (Patch)
209
210
211
212
213
214
Hose 0.50 x 4.00
Screw, Hex Head 1/4-28 X 1.75 W/Patch
Spring, Brake Arm Bias
Washer, Flat .28 X .73 X .063
Brake Assy. Spacer
Nylon
216 Kit,
Washer
Hex Lock Nut, 5/16-24 UNJF (Nylon Insert)
Spacer,
Screw, 5/16-24 X .75 (Patch)
Spring,
217
Nylon
Control
Arm, RTN Scissor, Outer
Arm, RTN Scissor, Inner
Kit, Breather Assembly
Plastic Hose Fitting
O-Ring
Valve
Plastic
Hose
35
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
310-2600 EXPLODED VIEW
111
126
58
52
143
55
210
110
66
68
107
8X 50
13
25
1
THICK RACE
11
TOWARD PISTONS
51
39
27
26
10
43
38
54
21
43
48
7
76
77
78
10X 50
137
42
41
142
40
7
4
49
135
136
123
5
6
120
26
126
67
58
73
63
70
8
33
30
31
68
60
62
64
19
208
34
215
215
207
19
82
81
53
35
81
81
216
12
24
14
15
3
209
150
78
2
3X 44
56
65
80
-
20w-50 OIL
100
-
SEALANT
134
-
SEAL KIT
INCLUDES ITEMS 4, 7,33,
40, 42, 50, 58, 60, 62, 66,
67, 68 83, AND 126
87
46
83
84
86
86
85
108
36
www.mymowerparts.com
310-2400/2600 IZT
®
No. DESCRIPTION
Housing-Main
Housing,
Cradle
Trunnion
Lip Seal
Screw
2 Lower
3 Center Section Assembly Kit
Center
Bushing
Bypass
Screw
Shock
Charge Relief Spring
Charge Check Ball
O-Ring
Plate
Bolt
Magnet
4 Lip
5 Spacer
6 Wire Retaining Ring
Ring
11
Bearing
10 Variable
Thrust Bearing 30 X 52 X 13
12 Input
13 Cover-Back
14 Spring,
15 10cc Cylinder Block Assy
10cc Cylinder Block
10cc Piston Spring
Piston Seat Washer
Piston
19 Washer
21 21cc Cylinder Block Assy
21cc Cylinder Block
21cc Piston Spring
Piston Seat Washer
21cc
24
25
Piston
Washer, Block Thrust
Thrust Bearing 42 X 68 X 16
26 Ball
27
Bearing
Wire Retaining Ring
30 Slot
31 Trunnion
33 Lip
35
Seal
34 Control
RTN Hex Lock Nut, 5/16-24 UNJF (Nylon Insert)
Standard Control Arm Nut
38 Bypass Plate Kit
39 Bypass
40 Lip
41 Bypass
42 Retaining Ring
43 Pin
44 Screw
46 Filter
49
50
51
52
53
Assembly
Hex Lock Nut 1/2-20 (Nylon Insert)
Screw, 1/4-20 X .75 Long
14T Bevel Gear
19T Bevel Gear
53T Spur Gear
54 Motor
58
60
62
63
Shaft
56 Axle
Seal, Lip 17 X 40 X 7
64
65
Seal Plug - Side
Retaining Ring - Axle
Retaining Ring
Bearing-Ball 20 X 47 X 14 (6204)
Bearing-Ball 20 X 47 X 12 (6205)
66 Seal
68 Retaining
70
Ring
LH, Brake Arm Service Assy
Brake
Clevis
73 Brake
Bushing 0.255 X 0.381 X 0.330
Hex Washer Head Screw, 1/4-20 X 7/8
Disc
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
310-2600 ITEMS LIST
No. DESCRIPTION
80 20W-50
81 Washer
82 Washer
83 O-Ring
84 Assembly
Gerotor
86 Screw
Plug
100 Sealant
Assembly
Hub
Lug
108 Nut, Hex 3/4-18
Fitting O-Ring Assembly 110
Plastic Hose Fitting
O-Ring
111 Cap Vent Assembly
Cap-Poppet
Vent
120 Pulley
123 Screw
126 Ring Retaining
134 Kit,
Seal, Lip 15 X35 X 7
Ring,
Seal, Lip 12 X 25 X 7
Seal, Lip 10 X 25 X 7
Ring, Retaining
Screw
Seal, Plug
Ring,
Ring, Retaining .440 External
Seal, Lip .98 X 1.85 X .276
Retaining
Retaining
Ring,
135 Washer
136 Fan, 6”, 10 Blade
137 Kit,
Washer
142
Magnet
207 Spacer,
208
Fan, 6”, 10 Blade
Hex Lock Nut 1/2-20 (Nylon Insert)
Pulley,
143
Washer
Brake
150 Ring
RTN
Screw, 5/16-24 X .75 (Patch)
209
210 Hose
215 Washer,
216 RTN,
Washer
Hex Lock Nut, 5/16-24 UNJF (Nylon Insert)
Arm,
Arm, RTN Scissor, Outer
Control
Spacer, RTN
Spring,
Screw, 5/16-24 X .75 (Patch)
Washer,
RTN
Arm, CW RTN, Inner
310-2400/2600 IZT
®
37
www.mymowerparts.com
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
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: 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”
38
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310-2400/2600 IZT
®
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
GLOSSARY OF TERMS
Hydrostatic Transaxle: A multi-component assembly including a gear 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: 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 contaminants.
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 circuit to the closed loop in a fluid power system.
System Pressure: The pressure 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.
310-2400/2600 IZT
®
www.mymowerparts.com
39
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
NOTES
40
www.mymowerparts.com
310-2400/2600 IZT
®
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
NOTES
310-2400/2600 IZT
®
www.mymowerparts.com
41
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
© 2008 Hydro-Gear
Rev. P2
Printed in U.S.A. www.mymowerparts.com
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