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310-2400
Integrated Zero-Turn Transaxle
Service and Repair Manual
BLN-51134
March 2001
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Table of Contents
Section
Page
Foreword ........................................................................................................................................ 1
Section 1 Description and Operation .......................................................................................... 2
Introduction ........................................................................................................................................................ 2
General Description............................................................................................................................................ 2
Hydraulic Schematic........................................................................................................................................... 3
External Features 310-2400L ............................................................................................................................. 4
External Features 310-2400R ............................................................................................................................. 5
Technical Specifications ..................................................................................................................................... 6
Product Identification .......................................................................................................................................... 6
Section 2 Safety............................................................................................................................. 7
Personal Safety.................................................................................................................................................. 7
Tool Safety......................................................................................................................................................... 7
Work Area Safety ............................................................................................................................................... 7
Servicing Safety ................................................................................................................................................. 7
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310-2400 IZT
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GENERAL DESCRIPTION
The 310-2400 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
WARNING
Actuating the bypass will result in the
loss of hydrostatic braking capacity.
The machine must be stationary on a
level surface and in neutral when
actuating the bypass.
The 310-2400 is configured for both floating
disc and cog style parking brakes.
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CHECK VALVE
CYLINDER
BLOCK
ASSEMBLY
CYLINDER BLOCK
ASSEMBLY
BYPASS
ACTUATOR
FIXED
SWASHPLATE
MOTOR
SHAFT
INPUT
SHAFT
VARIABLE
SWASHPLATE
VARIABLE
DISPLACEMENT
10cc PUMP
FIXED
DISPLACEMENT
21cc MOTOR
CHECK VALVE
RESERVOIR
TRANSAXLE
HOUSING
FILTER
HYDRAULIC SCHEMATIC
Figure 2 provides an illustration of the hydraulic
oil circuit. The oil supply for the hydraulic
system of the 310-2400 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.
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Back Cover
Axle Shaft
Hub
Assembly
Fill Port
Input Shaft
Seal Plug
Lower Cover
Bypass
Actuator
Control Arm
Assembly
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Back Cover
Axle Shaft
Hub
Assembly
Bypass
Actuator
Control Arm
Assembly
Fill Port
Input Shaft
Lower Cover
Seal Plug
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Brake Type
Disc, Parking
Cog, Parking
Weight of Unit
30 lb; 14 kg
PRODUCT IDENTIFICATION
The model and configuration of the 310-2400 IZT can be determined from the label shown in
Figure 3.
H Y D R O - G E A R
SULLIVAN, IL.
U.S.A.
Model
Number
13054
Hydro-Gear
Ref. Number
Made in U.S.A.
Serial Number
Year Built
Date
(Julian - day of year)
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TOOL SAFETY
WARNING
POTENTIAL FOR SERIOUS INJURY
Inattention to proper safety, operation, or
maintenance procedures could result in personal injury, or damage to the equipment.
Before servicing or repairing the 310-2400
IZT, fully read and understand the safety
precautions described in this section.
PERSONAL SAFETY
Certain safety precautions must be observed
while servicing or repairing the 310-2400 IZT.
This section addresses some of these
precautions but must not be considered an allinclusive source on safety information. This
section is to be used in conjunction with all
other safety material which may apply, such as:
1) Other manuals pertaining to this machine,
2) Local and shop safety rules and codes,
3) Governmental safety laws and regulations.
Be sure that you know and understand the
equipment and the hazards associated with it.
Do not place speed above safety.
Notify your supervisor whenever you feel there
is any hazard involving the equipment or the
performance of your job.
Never allow untrained or unauthorized personnel to service or repair the equipment.
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.
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Possible Cause
Corrective Action
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EXTERNAL MAINTENANCE
Regular external maintenance of the 310-2400
IZT should include the following:
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FLUID CHANGE
This transaxle is factory filled, sealed and does
not require oil maintenance. However, in the
event of oil contamination or degradation, oil
addition or change may alleviate certain performance problems.
It is essential that the unit exterior be free of
debris prior to fluid maintenance. The transaxle must be removed from the vehicle for oil
drainage from the top.
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
manufacturers suggestions outlined in
this manual. This will allow the space
needed for the oil to expand as it warms
up.
Table 3. Fluid Volumes for the 310-2400 IZT
Fluid Description
Volume
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11
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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.
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
vehicles 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 Manufacturers (OEMs) control linkage at the return
arm. Refer to Figure 7.
3. Start the engine and increase the throttle to
full engine speed.
AXLE ROTATION B
RETURN ARM
N
TIO
OTA
ER
AXL
AXL
ER
OTA
TIO
N
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The friction pack dampens or holds the operator control lever in its desired position.
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.
FRICTION PACK
ADJUSTING NUT
CONTROL ARM
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TRANSAXLE REMOVAL
GENERAL INSTRUCTIONS
CAUTION
USE CARE IN REMOVING THE HUB TO
PREVENT CRACKING.
LIMITED DISASSEMBLY
The following procedures are presented in the
order in which they must be performed to
completely disassemble the unit. Do not
disassemble the unit any farther than is
necessary to 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
28.
14
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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
Sockets
3/8"
1/2"
7/16"
9/16"
E-8 Torx Head
Wrenches
1/2"
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
110-150 in-lbs
200-360 in-lbs
110-150 in-lbs
525-700 in-lbs
210-270 in-lbs
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
Item
108
49
50
36
35
76/121
123/211
123
45
50
44
208
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)
15
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ASSEMBLY
DISASSEMBLY
INSPECTION
1. Inspect the back cover (13) for excessive
wear or damage.
50
13
16
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ASSEMBLY
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 orientation of the hub on the brake disc.
INSPECTION
1. Inspect the brake disc (73) for damaged
splines or gear teeth.
55
73
63
70
123
Figure 9. Cog Brake Assembly
17
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ASSEMBLY
DISASSEMBLY
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).
3. Remove the three brake yoke screws (123).
Remove the brake yoke (131).
4. Remove the stators (127) and rotor (73).
INSPECTION
1. Inspect the brake components for excessive
wear. Replace if necessary.
127
127
130
129
70
73
1
19
131
128
123
133
Figure 10. Disc Brake Assembly
18
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INSPECTION
DISASSEMBLY
ASSEMBLY
126
67
58
55
26
58
52
126
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ASSEMBLY
DISASSEMBLY
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.
20
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68
62
60
64
81
53
82
65
68
56
66
107
108
Figure 12. Axle Shaft & Spur Gear Assembly
21
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ASSEMBLY
DISASSEMBLY
INSPECTION
1. Inspect the lower housing (2) for excessive
wear or damage.
46
50
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ASSEMBLY
DISASSEMBLY
1. Install the motor shaft (54), bearing assembly (26) and wire retaining ring (27). Note:
The splines must be aligned when inserting the motor shaft (54).
INSPECTION
1. Inspect the gear (51), shaft (54) and bearing
(26) for wear or damage.
27
51
26
54
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INSPECTION
DISASSEMBLY
9. Remove the motor block thrust bearing assembly (25). Note: The thick race is located nearest to the pistons when assembled properly.
ASSEMBLY
24
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31
10
11
39
24
38
43
14
15
25
3
21
43
44
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ASSEMBLY
DISASSEMBLY
3. Install the input shaft (12), bearing assembly (8) and wire retaining ring (6), if removed.
5. Install a new input shaft lip seal (4). Remember to protect the seal during installation by covering the shaft with cellophane.
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.
26
310-2400 IZT
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7
4
5
6
8
33
30
31
1
9
Note: Cradle bearings are nonremovable. Shown removed for
illustration purposes only.
12
27
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ASSEMBLY AFTER
TEARDOWN
COMPLETE
28
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Sealant Path
Sealant Path
29
310-2400 IZT
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133
19
105
212
73
129
131
127
108
129
127
49
123
135
137
107
130
128
71
123
136
73
42
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41
40
99
5
6
13
63
56
68
66
65
120
126
7
58
4 26 67
56
81
50 (8X)
53
82
100
64
55
62
60
33
52
68
58
19
208
215
126
207
10
11
THICK RACE
TOWARD PISTONS
27
19
36
31
37
39
51
30
12
26
43
34
121
37 19
24
14
15
76
35
215
122
119
19
209
35
38
25
54
THICK RACE
TOWARD PISTONS
3
21
43
44 (3X)
310-2400 IZT
46
100
50 (10X)
35
8020W-50 OIL
134SEAL KIT
INCLUDES ITEMS 4, 7, 33, 40, 42,
50, 58, 60, 62, 66, 67, 68 AND 126
216
70
30
211
213
214
DESCRIPTION
No.
DESCRIPTION
Kit, Housing-Main
Housing, Main
Cradle Bearing
Lip Seal
Trunnion Bushing
Lower Housing
Center Section Assembly Kit
Bypass Plate
Check Plug Assembly
Center Section
Bushing
Screw
Lip Seal
Spacer
Wire Retaining Ring
Retaining Ring
Ball Bearing
Cradle Bearing
Variable Swashplate
Thrust Bearing 30 X 52 X 13
Input Shaft
Cover-Back
Spring, Block
10cc Cylinder Block Assy
10cc Cylinder Block
10cc Piston Spring
Piston Seat Washer
10cc Piston
Washer
21cc Cylinder Block Assy
21cc Cylinder Block
21cc Piston Spring
Piston Seat Washer
21cc Piston
Washer, Block Thrust
Thrust Bearing 42 X 68 X 16
Ball Bearing
Wire Retaining Ring
Slot Guide
Trunnion Arm
Lip Seal
RTN Control Arm
Standard Control Arm
RTN Hex Lock Nut, 5/16-24 UNJF (Nylon Insert)
Standard Control Arm Nut
Stud-Long 5/16-24
Friction Puck
Bypass Plate
Bypass Actuator
Lip Seal
Bypass Arm
Retaining Ring
Pin
Screw
Filter
Hex Lock Nut 1/2-20 (Nylon Insert)
Screw, 1/4-20 X .75 Long
14T Bevel Gear
19T Bevel Gear
53T Spur Gear
Motor Shaft
Brake Shaft
Shaft, Axle 25mm X 14 (D,D)
Axle Shaft
Seal, Lip 17 X 40 X 7
Seal Plug - Side
Retaining Ring - Axle
Retaining Ring Kit
Bearing-Ball 20 X 47 X 14 (6204)
Bearing-Ball 20 X 47 X 12 (6205)
Seal
Retaining Ring
Retaining Ring-Axle
Arm, Brake
RH, Brake Arm Service Assy
Brake Arm
Clevis Pin
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
76
80
81
82
99
100
105
2
3
4
5
6
7
8
9
10
11
12
13
14
15
19
21
24
25
26
27
30
31
33
34
35
36
37
38
39
40
41
42
43
44
46
49
50
51
52
53
54
55
56
58
60
62
63
64
65
66
67
68
70
71
73
107
108
110
111
119
120
121
122
123
126
127
128
129
130
131
133
134
135
136
137
207
208
209
211
212
213
214
215
216
31
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32
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33
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2001 HYDRO-GEAR
Printed in U.S.A.
34
310-2400 IZT
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