310-0500/0800 IHT
Contents
1. T NN 310 0500 0800 IHT Page 23 2006 HYDRO GEAR Printed in U S A Rev P22. IHT Flow Illustration 310 0500 0800 IHT Page 3 310 0500 0800 IHT Maintenance Fluids Greases The fluids used in Hydro Gear products have been care fully selected and only equivalent or better products should be used Typically an engine oil with a minimum rating of 55 SUS at 210 F 98 9 C and an API classification of SL CD is recommended 20W 50 engine oil has been selected for use by the factory The grease used in the manufacture of Hydro Gear prod ucts is Exxon Polyrex EP2 grease and should be substi tuted with equivalent products only if it is not readily available in your area NOTE This grease is not compatible with all grease types Safety Precautions Certain procedures may require the vehicle to be disabled wheels raised off the ground engine disconnected etc in order to prevent possible injury to the technician and bystanders Some cleaning solvents are flammable To avoid possible fire do notuse cleaning solvents in an area where a source of ignition may be present The loss of hydrostatic driveline power may result in the loss of hydrostatic braking capacity Proper brake mainte nance becomes very important should this condition develop i 1 NNI ZZ 270 Maintenance Check the transaxle cooling fan for broken or distorted blades and check to see that the fan is securely fastened Replace the fan if damaged
3. Hydro Gear We set the wheels in motion 9 310 0500 0650 0750 0800 Integrated Hydrostatic Transaxle Service and Repair Manual BLN 50432 Revision October 2006 310 0500 0800 IHT Table of Contents Table of Contents Introduction 9 General Description 0 04600 4 Fluids Greases 4 Safety 4 Maintenance 4 Troubleshooting Diagram 2 9 Troubleshooting Chart 6 Minor 7 8 General Information 7 Shaft Seal 7 Parking Brake sss 8 Control Arm Friction 9 Oil Level Major 2 0 0 4 9 19 General Information 9 Disassembly Procedures 9 13 Reconditioning 8 Replacement of Components 13 Assembly 14 19 Oil Fill amp Start Up Procedures 19 310 0500 Parts Drawing amp Parts List 20 21 310 0750 Parts Drawing amp Parts List 22 23 Page 2 310 0500 0800 IHT Introduction General Description 310 0500 0800 IHT Introduction The purpose of this manual is to provide information useful in servicing the Hydro Gear Integrated Hydrostatic Tr
4. NOTE Not all vehicles are equipped with a cooling fan refer to your vehicle manual Keep the transaxle clean Grass clippings and dirt will effectthe cooling efficiency of the fins on the housing Avoid high pressure washing compressed air is the preferred method of removing loose debris Inspect the brake for proper operation If the brake fails to stop the vehicle or hold on a 30 slope adjustments are necessary You should also make sure it fully disengages when the pedal is released Check to make sure the bypass actuator and linkage is operational The bypass must be fully released during operation of the vehicle Inspectthe transaxle for leaks at lip seals or damage to the housing Check the oil level and add oil as necessary to bring it up to the proper level D IN NN NS 17772222 2 2 a 222 555 NS SS A D Ill 2 2 NY 310 0500 Integrated Hydrostatic Transaxle Page 4 310 0500 0800 IHT Troubleshooting Diagram 310 0500 0800 IHT OPERATES IN ONE DIRECTION ONLY CHECK CONTROL REPAIR OR LINKAGE REPLACE TRANSAXLE DEFECTIVE REPAIR OR REPLACE CHECK LEVEL IN UNIT LOW DEFECTIVE FIEL TO REPAIR OR ADJUST TO ADJUST PROPER LEVEL REPLACE PROPER SETTING BYPASS VALVE LINKAGE CHECK OIL CHECK HOUSING CONDITION PUR EXCESSIVE DEBRIS BUILDUP DEFECTIVE OK DEFECTIVE DEFECTIVE
5. CHANGE OIL CLEAN OFF REPAIR OR REDUCE DEBRIS REPLACE VEHICLE LOAD REPAIR OR REPLACE TRANSAXLE NOISY UNDER LOAD CHECK OIL CHECK LEVEL IN UNIT EXCESSIVE VEHICLE LOAD LOW V FILL TO REDUCE ADJUST BRAKE ADJUST PROPER LEVEL VEHICLE LOAD TO PROPER BYPASS VALVE SETTING LINKAGE CHECK OIL REPAIR OR CHECK FOR LOOSE CONDITION REPLACE LINKAGES AND METAL TO TRANSAXLE METAL CONTACT POINTS DEFECTIVE CHANGE OIL REPAIR OR REPLACE LOOSE PARTS WILL REQUIRE TRANSAXLE REMOVAL 310 0500 0800 IHT Page 5 310 0500 0800 IHT Troubleshooting Chart WARNING THE VEHICLE SHOULD BE ON LEVEL GROUND AND THE ENGINE DISABLED BEFORE PERFORMING ANY ADJUSTMENTS SYMPTOM OPERATES IN ONE DIRECTION ONLY POSSIBLE CAUSE Inspect control linkage Inspect drive belt amp pulleys SYMPTOM NOISY POSSIBLE CAUSE Check oil level amp condition Checkfor excessive loading Check brake setting Check for loose parts Check bypass valve linkage operation SYMPTOM LOW POWER POSSIBLE CAUSE Check engine RPM Check drive belt amp pulleys Check oil level amp condition Checkfor excessive loading Check brake setting Check for loose parts Check bypass valve linkage operation SYMPTOM OPERATING HOT POSSIBLE CAUSE Check for debris buildup Check oil level amp condition Checkfor excessive loading Check brake setting Page 6 CORRECTIVE ACTION Repair or replace Repair or repla
6. adequate As with any precision equipment all parts must be kept free of foreign materials and chemicals Protect all exposed sealing surfaces and open cavities from damage and foreign material The outer surfaces should be cleaned before beginning any repairs It is recommended that all seals be replaced Lightly lubricate all seals with a clean petroleum jelly prior to assembly It is recommended that parts requiring replacement be replaced as a complete assembly kit as shown in the service parts drawings on pages 20 25 Priorto performing Major Repairs on the IHT remove the transaxle from its installed location and remove any external components such as the brake arm brake actu ating pins control arm and friction pack if included cooling fan and input pulley orframe mounting hardware NOTE Thoroughly cleanall exposed surfaces priorto any further disassembly Disassembly Procedures Drain the oil by removing the breather assembly and positioning the IHT sothatthe breather portis downto allow the oil to drain thoroughly Drain Oil From Breather Port 310 0500 0800 IHT Position and secure the IHT with the upper housing down to allow access to the twenty housing assembly cap screws Remove Housing Assembly Bolts Using the appropriate tool remove the twenty assembly screws NOTE Prior to October 27 1993 a 3 16 drive internal hex head cap screw was used at that time a change was made to an E 8 exter
7. is not be reusable Remove Input Shaft Lip Seal Remove the input shaft bearing retaining ring 310 0500 0800 IHT Pump Input Shaft Assembly Reposition housing and remove the displacement control shaft and lip seal Inspect the housing for damage Reconditioning and Replacement of Parts All parts should be thoroughly cleaned in a suitable solvent All sealant material MUST be removed from the housing halves prior to reassembly Inspect all parts for damage nicks or unusual wear patterns Replace all parts having unusual excessive wear or discoloration Inspect the sealing surfaces bearing surfaces and shaft splines Polish the sealing areas on the shafts if neces sary Replace any worn or damaged parts The running surfaces of the cylinder blocks MUST be flat and free from scratches If scratches or wear are found on the running surface of the cylinder block or center section replace the parts Clean and lightly oil parts prior to assembly of the IHT Page 13 310 0500 0800 IHT Major Repairs Assembly Procedures Be sure to torque all threaded parts to the recommended torque levels Replace all o rings and shaft seals CAUTION Most parts have critical high tolerance surfaces Care must be exercised to prevent damage to these surfaces during assembly Protect exposed surfaces openings and ports from damage or foreign material Install the displacement control shaft T am Install Displac
8. machine frame Input Shaft Seal Removal 310 0500 0800 IHT Toremove the input shaft seal carefully pull the seal out of the housing bore with a hook type tool or a slide hammer type puller Care must be taken to avoid damage to the housing bore or to the shaft sealing surface Lubricate the new seal prior to installation with a petroleum jelly Wrap the shaft spline keyway with a thin plastic or cellophane tape to prevent damage to the new seal lip during installation Slide the seal over the shaft and press it into the housing bore Be careful not to damage the seal The seal should seat against the retaining ring The displacement control shaft seal and the bypass actuator shaft seal may be replaced following similar procedures ee Input Shaft Seal Installation Page 7 310 0500 0800 IHT Minor Repairs Parking Brake The brake was set at a specific running clearance approximately 0 030 762 mm between the discs to the Original Equipment Manufacturers specifications Refer to the vehicle service manual for the correct clearance Place a feeler gage between the two outer discs if the clearance is not correct make the necessary change with the brake retainer nut Brake Adjustment Bottom View NOTE Twoversions of the brake retainer nuts have been used Early production employed a Nylock type nut while current production is using a castellated nut with a cotter pin
9. wear Inspect the differential bevel gears by rotating the axle ends Inspect the final drive gear teeth for excessive wear or damage Check the differential assembly screws for proper torque For the 310 0500 they should be torqued to 15 26 ft lbs 20 35 Nm while the 310 0750 should be torqued to 11 15 ft lbs 15 20 Nm Inspect the journal bearings inside the differential housing for excessive wear by feeling the shafts for an unreason able amount of play lfexcessive wear or damage has been found the complete assembly must be replaced 310 0750 Axle Differential Components 310 0500 0800 IHT Major Repairs 310 0500 0800 IHT Disassembly Procedures Remove the brake rotors and stators by sliding one ata time off of the end of the splined motor shaft Removal and Inspection of Brake Rotors Inspect each side of both rotors for excessive wear or damage Inspect the rotors internal splines for excessive wear or damage Inspect the stators for excessive wear and damage Replace rotors and stators as a complete kit if excessive wear or damage is found and inspect all other mating parts Remove the oil filter After inspecting the filter for unusual particles that it may have trapped dispose of it properly and replace it with a new oil filter during reassembly Using a 9 16 socket or box end wrench remove the three assembly bolts retaining the center section in the upper housing CAUTION The
10. 1 Nm following the patterns illustrated below NOTE The group of bolts around the front of the housings have the same sequence number because they are in stalled simultaneously at our factory the order in which you torque them should not be important Suggested Bolt Torque Sequence 310 0500 Bolt Torque Sequence Suggested Bolt Torque Sequence 310 0750 Bolt Torque Sequence After torquing all bolts wipe off any excess sealant from the seam of the housings Reposition the transaxle assembly and check the bypass actuator and axle shafts for freedom of movement The axle shafts should not lock up but may be tight while the bypass actuator must rotate freely Page 18 Torque the nut on the brake bolt from 120 to 185 in Ibs 15 5 21 Nm i Tighten Brake Bolt Nut Install a new lip seal on the displacement control shaft amp bypass actuator as described in the Minor Repairs Sec tion Install the brake pins and brake arm Install the washer and adjustment nut Adjust the brake clearance
11. and the bypass actuator into the housing Install Aligning Pins and Bypass Actuator Install the washers and a new lip seal onto the motor shaft Install the motor shaft into the center section Install Motor Shaft Install the bypass plate small end first into the center section Install Bypass Plate Page 15 310 0500 0800 IHT Major Repairs Assembly Procedures Lubricate the running faces and install the motor block kit onto the motor shaft Install Motor Block Kit Position the washers and seal and install the center section assembly onto the aligning pins and pump input shaft Position Center Section Assembly Page 16 Insertthe three assembly bolts into the center section and press center section down onto the aligning pins and pump input shaft until seated on mounting bosses While holding the center section in position torque the bolts evenly from 525 in Ibs to 700 in Ibs 59 79 Nm Install Center Section Assembly Install the motor thrust bearing with the thicker race towards the pistons by compressing the piston springs and sliding the bearing assembly in to place NOTE The tool being shown is an example of what you will need to compress the pistons and allow the bearing to be installed Install Motor Thrust Bearing 310 0500 0800 IHT Major Repairs 310 0500 0800 IHT Assembly Procedures Fill the axle pockets of the upper housing with Exxon Polyrex EP2 grease inside of be
12. ansaxle IHT This manual includes component descrip tion troubleshooting maintenance and repair procedures Atransaxle normally will not require servicing during the life of the vehicle in which it is installed Should servicing be required the unit must be removed from its installed location and thoroughly cleaned before beginning most procedures General Description The Integrated Hydrostatic Transaxle 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 The IHT uses a variable pump with a maximum displace ment of 10cc per revolution and a motor with a fixed displacement of 21cc per revolution The variable displace ment pump features a cradle swashplate with a direct proportional displacement control Reversing the direction of tilt of the swashplate reverses the flow of oil from the pump to the motor and thus reverses the direction of the motor output rotation Thefixed displacement motor uses a fixed swashplate The pump and motor are of the axial piston design and both utilize spherical nosed pistons which are held against a thrust race by internal compres sion springs The IHT has a self contained fluid supply and an integral filter The fluid is forced through the filter by a positive head on the fluid in the housing reservoir with an assist by the negative pressure created in th
13. aring location NOTE This grease is not compatible with all grease types Do not overfill and wipe off any excess grease or sealant will not cure properly Install the washers and seals onto the differential axle assembly and align them for installation Install the differential axle assembly into the housing Install Differential Axle Assembly Install a new filter onto the center section check valve plate Install the rotors and stators Install a stator then a rotor hub to inside then a stator then a rotor hub to inside then two stators Install the brake bolt with nut into the upper housing 2 Install Brake Components 310 0500 0800 IHT Fixture the lower housing and apply a thin bead of sealant as shown in the following two examples NOTE The drawings below may not appear the same as the factory sealant application but are the recommended patterns Apply sparingly NOTE Sealant must be of good quality oil and heat resistant 310 0750 Sealant Application Page 17 310 0500 0800 IHT Major Repairs Assembly Procedures Position the lower housing onto the upper housing and secure with assembly bolts Torque the bolts from 135 in lbs to 185 in Ibs 15 25 2
14. as described in the Minor Repairs Section Refer to the Minor Repairs Section before installing the control arm and friction pack XN Brake and Control Arm Components Install the bypass actuator arm and retaining ring Use care to avoid over extending the retaining ring 310 0500 0800 IHT Major Repairs 310 0500 0800 IHT Assembly Procedures Prior to adding oil to the IHT it is recommended that you test for leaks This may be performed with a small hand pump or by using compressed air and a regulator Do not allow more than 10 PSI 69 bar to be applied or seal damage may occur To locate a leak apply a soap mixture around the housing seam and at all lip seals Do not submerge unit or the brake will be damaged Oil Fill amp Start Up Procedures Fill the IHT with a 20W 50 engine oil The correct volume for fill should be 2 1 2 quarts 80 ounces 2 37L for both the 310 0500 and the 310 0750 Itisrecommended thatthe unitbe purged priorto installing into the vehicle frame The following is the suggested purging procedures for repaired transaxles 1 Spin the input shaft in a clockwise direction at 1000 1500 RPM This may be performed in a drill press or equivalent 2 Engage actuate the bypass 3 Stroke the control lever forward for five seconds and then reverse for five seconds Do this three times in each direction 4 Return the control
15. ce CORRECTIVE ACTION Fill to proper level or change oil Reduce vehicle loading Adjust brake to proper setting Repair or replace loose parts Repairor replace linkage CORRECTIVE ACTION Adjust to correct setting Repair or replace Fill to proper level or change oil Reduce vehicle loading Adjust brake to proper setting Repair or replace loose parts Repairor replace linkage CORRECTIVE ACTION Clean off debris Fill to proper level or change oil Reduce vehicle loading Adjust brake to proper setting 310 0500 0800 IHT Minor Repairs 310 0500 0800 IHT Minor Repairs General Information Minor Repairs may be performed following the procedures in this section without voiding the unit warranty Cleanliness is a primary means of assuring satisfactory life of either new or repaired units Cleaning parts by using solvent wash and air drying is usually adequate As with any precision equipment all parts must be kept free of foreign materials and chemicals Protect all exposed sealing surfaces and open cavities from damage and foreign material The outer surfaces of the transaxle should be cleaned before beginning any repairs Shaft Seals Lip type seals are used on the pump input shaft the displacement control shaft and the bypass actuator shaft of the transaxle These seals can be replaced without major disassembly of the unit Replacement of these seals generally requires removal of the transaxle from the
16. e pump pistons as they operate Charge check valves in the center section are used to control the makeup flow of fluid to the low pressure side of the loop The IHT is filled and tested at the factory and should not require fluid or filter changes unless the fluid becomes contaminated cam style block lifting bypass is utilized in the IHT to permit moving the vehicle for short distances at a maxi mum of 2 mph 3 2 km hr without starting the engine WARNING Actuating the bypass will result in the loss of hydro static braking capacity The machine must be station ary and on a level surface and in neutral when actuating the bypass The IHT includes an integral differential which utilizes heavy duty heat treated bevel gears A style arm is utilized to actuate an in line floating multidisc parking brake The brake discs are enclosed in a cavity that is sealed from the oil supply CYLINDER BLOCK ASSEMBLY INPUT SHAFT 722222772 mm Io iw CYLINDERBLOCK CHECK VALVE ASSEMBLY BYPASS ACTUATOR FIXED SWASHPLATE BRAKE ASSEMBLY I WU EF Y Y VARIABLE A SWASHPLATE VARIABLE DISPLACEMENT 10cc PUMP FIXED DISPLACEMENT 21CC MOTOR CHECKVALVE FINAL DRIVE DIFFERENTIAL SS B RESERVOIR J FILTER TRANSAXLE HOUSING
17. ement Control Shaft Install the pump input shaft assembly and retaining ring into the housing Install Pump Shaft Assembly Install the pump shaft lip seal Page 14 Reposition the upper housing and install the cradle bear ings Install the slot guide block onto the displacement control shaft Install the swashplate assembly into the housing The slot onthe swashplate mustengage the slot guide block on the displacement control shaft Use a tool such as a screw driver to hold the guide block in position while installing the swashplate Swashplate Installation Install the thrust washer and and pump block spring onto the pump shaft NOTE To simplify the installation of the pump block wrap a rubber band snugly around the pistons This is intended to hold the pistons in their bores as the block kit is handled during installation 310 0500 0800 IHT Major Repairs 310 0500 0800 IHT Assembly Procedures With the swashplate in the neutral 0 angle position lubricate the running surfaces and install the block kit onto the pump input shaft Make sure the splines engage properly Install Pump Block Kit For 310 0750 Models Only Install the pinion gear and washers onto the jackshaft Install the jackshaft assembly into the housing and torque the bolts from 120 05 to 170 in Ibs 13 5 19 2 Nm 4 1 p 310 0500 0800 IHT Install the aligning pins
18. for retainment OLD STYLE NEW STYLE Brake Retainer Nut Variations Page 8 Control Arm amp Friction Pack NOTE The control arm and friction pack vary between models and is not used on some The OEM have estab lished individual specifications for the proper adjustments Refer to vehicle service manual for the proper procedures OLD NON ADJUSTABLE FRICTION WITHOUT WASHER WITH WASHER ADJUSTABLE FRICTION Friction Pack Variations Oil Level To check the oil level you must first remove the breather fitting from the housing NOTE Make sure the surrounding area has been thor oughly cleaned prior to removal of the fitting to prevent the introduction of contamination into the oil The oil level should be between 1 25 and 2 0 31 75 50 8 mm from the top of the housing for the 310 0500 and between 1 00 and 1 75 25 4 44 45 mm from the top of the housing for the 310 0750 310 0500 Cil Levels 310 0750 310 0500 0800 IHT Major Repairs 310 0500 0800 IHT General Information Major Repairs described in the following sections are for the complete disassembly and reassembly Major Repair of the IHT and will void all product warranty unless license to perform said Major Repair was previously obtained from an Authorized Representative of Hydro Gear Cleanliness is a primary means of assuring satisfactory life on neworrepaired units Cleaning parts by using a solvent wash and air drying is usually
19. lever to neutral 5 Disengage the bypass 6 Stroke the control lever forward for five seconds and then reverse for five seconds Do this three times in each direction NOTE may be necessary to repeat these steps in the vehicle to fully purge the IHT 310 0500 0800 IHT Check the oil level after fully purging the unit of air It should be between 1 25 and 2 0 31 75 50 8 mm from the top of the housing for the 310 0500 and between 1 00 and 1 75 25 4 44 45 mm from the top of the housing for the 310 0750 310 0500 Oil Level After installing the IHT make sure all linkages and actua tors are functioning properly Referto the Troubleshooting Section Page 19 310 0500 Parts Drawing amp Parts List 310 0500 0800 IHT 155139 v6 1 1 35 OSMOC 99 310 0500 0800 IHT Page 20 310 0500 Parts Drawing 8 Parts List 310 0500 0800 IHT 6 _ mm Dese emen 1 NETT NN 8 pe pem _ 310 0500 0800 IHT Page 21 310 0500 0800IHT 310 0750 Parts Drawing amp Parts List E O 2 O d 1 tD mp 94 GREASE Page 22 310 0500 0800 IHT 310 0750 Parts Drawing amp Parts List 310 0500 0800 er _
20. nal drive Torx screw Loosen the nut on the brake arm mounting bolt Separate the two housing halves by applying pressure as shown with two large straight blade screw drivers Use caution to prevent damage to the mating sealing surfaces as you separate the two halves NOTE The sealant will make the two halves difficult to separate Separate Housing Halves Page 9 310 0500 0800 IHT Major Repairs Disassembly Procedures All components should remain in the upper housing positioned down CAUTION The axle differential assembly may stick as the lower housing is being lifted off of the upper housing Inspect the lower housing for damage Inspect the axle journal bearing pockets for excessive wear Inspect the brake rotor stator pocket for excessive wear NOTE Prior to reassembly the lower housing must be thoroughly cleaned and old sealant must be removed 310 0750 components in Upper Housing Liftthe axle differential assembly out of the upper housing NOTE Itwill be necessary to remove any burrs or rust from the axle ends prior to the removal of the two bronze bearings or damage to the bearings will occur Remove the two bronze journal bearings four lip seals and two flat washers from the axle ends Remove Axle Differential Assembly Page 10 NOTE The lip seals must not be re used during reassem bly Inspect the bronze bearings for excessive wear Inspect the axle ends for damage or excessive
21. pump and motor piston springs may push the center section assembly out of position while you remove these bolts Remove Center Section Assembly Remove the center section assembly from the housing The pump block assembly should remain in the upper housing on the input shaft but may stick to the center section Checkthe check valve plate bolttorque but do not remove Twostyles of check plates have been used one has three bolts while the other has four The one with four bolts should be torqued from 170 to 240 in lbs 19 2 27 Nm while the one with three bolts should be torqued from 135 to 185 in lbs 15 25 21 Nm CAUTION The aligning pins motor shaft bypass plate pump block and motor block assemblies are NOT retained to the center section or the upper housing and may become separated from the assem bly during removal Remove Oil Filter 310 0500 0800 IHT Center Section Motor Shaft Page 11 310 0500 0800 IHT Major Repairs Disassembly Procedures Remove the motor block assembly from the motor shaft and inspect for unusual wear or damage The pistons should fit with very little side clearance in the block bores but must slide freely Remove the motor shaft washers and bypass plate from the center section and inspect for unusual wear or damage Inspect the center section running surfaces for unusal wear or damage Remove the pump block assembly block thrust washer and spring fromthe input shaftand inspectfo
22. r unusual wear or damage The pistons should fit with very little side clearance in the block bores but must slide freely Remove Pump Block Assembly Page 12 For310 0750 Models Only Removethe two internal hex head cap screws retaining the jack shaft to the housing with a 5mm hex wrench and remove the jack shaft pinion gear assembly from the housing Remove Jack Shaft Pinion Gear Assembly Inspect the jack shaft running surface for excessive wear ordamage Inspectthe pinion gear borefor excessive wearor damage Inspect the pinion gear teeth for excessive wear or dam age If excessive wear or damage was found the complete assembly should be replaced Jack Shaft Pinion Gear Components 310 0500 0800 IHT Major Repair 310 0500 0800 IHT Disassembly Procedures Remove the motor thrust bearing assembly swashplate kit and cradle bearings from the housing and inspect for unusual wear or damage Remove the pump input shaft assembly from the housing Inspect the shaft and bearing for unusual wear or damage Swashplate Kit and Thrust Bearing Assembly Remove the slot guide block from the displacement control shaft Remove the bypass actuator from the housing Reposition the housing and remove the input shaft lip seal from the housing bore Ahook type tool may be used to pry the seal out Care must be taken to avoid damage to the housing bore shaft sealing surface or bearing Once removed the seal
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