Hydro-Gear ZT-2800 Service And Repair Manual
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Hydro-Gear ZT-2800 Service And Repair Manual

Integrated zero-turn transaxle
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ZT-2800
/ZT-3100™/ZT-3400™
®
Integrated Zero-Turn Transaxle
Service and Repair Manual
BLN-52441
February 2011

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Summary of Contents for Hydro-Gear ZT-2800

  • Page 1 ZT-2800 /ZT-3100™/ZT-3400™ ® Integrated Zero-Turn Transaxle Service and Repair Manual BLN-52441 February 2011...

  • Page 2: Table Of Contents

    How To Use Service Schematic ....40 Control Arm Assembly ........ 15 Notes ............41 Parking Brake Adjustment ......16 ZT-2800 Exploded View & Parts List ..42-43 ® Parking Brake Assembly......17 ZT-3100 Exploded View & Parts List ..42-43 Brake Arm Assembly ........

  • Page 3: Foreword

    EETC (Equipment & Engine Training and the quality leader in everything we do. Council) at (262) 367-6700 or their Hydro-Gear This Service and Repair Manual is designed Central Service Distributor. Many distributors to provide information useful in servicing and will be hosting certification testing.

  • Page 4: Description And Operation

    ® ZT-2800 , ZT-3100™ and ZT-3400™ Integrat- The ZT-2800 is designed for both charged and ® uncharged product versions. In the uncharged ed Zero-Turn Transaxles. This manual includes the general descriptions, hydraulic schematics,...

  • Page 5: Hydraulic Schematic

    System Check Valves Filter Charge Relief Charge Pump figure 1, Hydraulic schematic with Charge pump Vent Case Reservoir Input Shaft Bypass Motor Pump Motor Shaft System Check Valves Filter figure 2, Hydraulic schematic without Charge pump (ZT-2800) ZT-2800 ZT-2800 /ZT-3100/ZT-3400™ ® ®...

  • Page 6: External Features

    ZT-2800 /ZT-3100 ( ® ZT-3400 similar Axle Shaft Main Housing Bypass Arm Control Arm — Top View — Drain Port Top Port Plug (For Horizontal Installation) Parking Brake Arm Side Cover — inboard View — ZT-2800 /ZT-3100™/ZT-3400™ ®...
  • Page 7 ZT-2800 /ZT-3100 ® (ZT-3400 similar) Input Shaft Axle Shaft Oil Filter Expansion Port (For Horizontal Installation) — Outboard View—Left (standard Control) — Fan and Pulley Kit Return To Neutral Assembly Charge Pump — Outboard View—right (return To neutral Control) —...

  • Page 8: Technical Specifications

    Unit 32 lb (14.5 kg) 33 lb (14.9 kg) prOdUCT idenTifiCaTiOn The model and configuration of the ZT-2800, ZT-3100 and ZT-3400 can be determined from the label found on the transaxle. HYDRO-GEAR ZH-KCEE-1B8C-1BXX ZH-KCEE-1B8C-1BXX 5 186 B4 476...

  • Page 9: Safety

    Discard used cleaning material in the appropri- Never allow untrained or unauthorized person- ate containers. nel to service or repair the equipment. ZT-2800 ZT-2800 /ZT-3100/ZT-3400™ ® ®...

  • Page 10: Troubleshooting

    Brake Partially Engaged Disengage Brake, Replace Broken or Missing Brake Return Spring Tr a ns a xle leaks oil Damaged seals, housing, or gaskets Replace damaged components Air trapped in hydraulic system Purge hydraulic system, Page 12 ZT-2800 /ZT-3100™/ZT-3400™ ®...

  • Page 11: Service And Maintenance

    The fluids used in Hydro-Gear products have been carefully selected, and only equivalent, or better products should be substituted. ZT-2800 /ZT-3100/ZT-3400™ ®...

  • Page 12: Filter And Filter Guard

    NOTE: As a general rule, use the low end of the torque specification on fasteners inspection when reassembling the unit. 1. Inspect all parts for excessive wear or dam- age. Replace if necessary. Units will have installed, the fitting (111) or the plug (5). Drain port (for horizontal installation) When refilling the transaxle with oil, remove the port plug (5), if installed, and plug (11). Fill until the oil reaches the lower lip of port (11) on side cover. figure 4, filter and guard ZT-2800 /ZT-3100™/ZT-3400™ ®...

  • Page 13: Fluid Change Procedure

    “Full Cold” line is gasket of the new replacement filter (Hydro- reached on the Hydro-Gear expansion tank Gear part number 52114). (refer to vehicle owner’s manual for specific 4.

  • Page 14: Purging Procedures

    Before starting, make sure the transaxle is at forward and reverse at normal speeds, then the proper oil level. If it is not, fill to the specifi- the transaxle is considered purged. cations outlined in this manual. ZT-2800 /ZT-3100™/ZT-3400™ ®...

  • Page 15: Return To Neutral Setting

    2. Remove the Original Equipment Manufac- and 4. Refer to Figure 7. turer’s (OEM’s) control linkage at the control arm. ROTATION "B" ROTATION "A" RTN Adjusting Screw Speed and Direction Control Arm figure 7, return to neutral setting ZT-2800 ZT-2800 /ZT-3100/ZT-3400™ ® ®...

  • Page 16: Return To Neutral Assembly

    (211), and cannot be serviced separately. Refer to “Seal Kit” in the Items List on pages 43 or 45. inspection 1. Inspect all parts for excessive wear or dam- age. Replace if necessary. “R ” efeR to etuRn to eutRal etting figure 8, return to neutral assembly ZT-2800 /ZT-3100™/ZT-3400™ ®...

  • Page 17: Control Arm Assembly

    Refer to “Seal Kit” in the reassembling the unit. Items List on pages 43 or 45. inspection 1. Inspect all parts for excessive wear or dam- age. Replace if necessary. figure 9, Control arm assembly ZT-2800 ZT-2800 /ZT-3100/ZT-3400™ ® ®...

  • Page 18: Parking Brake Adjustment

    ZT-2800/ZT-3100 parKing BraKe adjUsTMenT (Code 1 or 2) Character #7 in the model number code = 1 4. While holding the parking brake handle or 2. (102) firmly onto the splines, remove clip (103) from the shaft tip. Example: ZX-XXXX-1XXX-XXXX 5. Before removing the parking brake handle (102) scribe a reference mark between the handle and shaft tip (101).

  • Page 19: Parking Brake Assembly

    ZT-2800/ZT-3100 parKing BraKe asseMBLY (Code 1 or 2) inspection Character #7 in the model number code = 1 or 2. 1. Inspect all parts for excessive wear or dam- Example: ZX-XXXX-1XXX-XXXX age. Replace if necessary. 2. Inspect the splines on the handle and brake Refer to Figure 12 cam shaft.

  • Page 20: Brake Arm Assembly

    1. Reassemble all parts in the reverse order NOTE: The orientation of the brake arm and of disassembly. brake shaft to one another is very im- portant. 2. Remove the retaining clip (103). 3. Remove the brake arm (102). Brake Arm (102) Reference Mark Brake Shaft (101) Brake Shaft (101) figure 13, parking Brake ZT-2800 /ZT-3100™/ZT-3400™ ®...

  • Page 21: Hub Removal

    2. Remove the hex retaining nut (3/4-16) from the center of the axle hub and discard. 3. Back out the hub removal tool bolt with a 1-1/8” socket before installing the hub re- moval tool to the axle hub. ZT-2800 /ZT-3100/ZT-3400™ ®...

  • Page 22: Tear Down And Reassembly

    Hydro-Gear replacement parts of maintenance. Cleaning of all parts by us- found at www.hydro-gear.com or at your Hydro- ing a solvent wash and air drying is usually Gear Central Service Distributor.

  • Page 23: Tools

    Friction Pack Stud Nut, Hex 8-32 (Nylon insert) 30 – 36 lb-in (3.4 - 4.0 Nm) Brake Spring Nut As a general rule, use the low end of the torque spec on fasteners when reassembling the unit. ZT-2800 /ZT-3100/ZT-3400™ ®...

  • Page 24: Transaxle Removal

    2. When tightening the fasteners, refer to the summary of the assembly procedures, in the table on page 21 for the required torque order in which they should occur, is given on values. page 38. NOTE: As a general rule, use the low end of the torque specification on fasteners when reassembling the unit. Figure 15, Fan/Pulley Kit (207) Configuration “A” ZT-2800 /ZT-3100™/ZT-3400™ ®...
  • Page 25 21 for the required torque table on page 21 for the required torque values. values. NOTE: As a general rule, use the low end of the torque specification on fasteners when reassembling the unit. Figure 17, Fan/Pulley Kit (207) Configuration “C” Figure 16, Fan/Pulley Kit (207) Configuration “B” ZT-2800 /ZT-3100/ZT-3400™ ®...
  • Page 26 (Continued) Refer to Figure 18 disassembly FAN AND PULLEY KIT (207) CONFIGURATION “D” (ZT-2800/ZT-3100) 1. Remove the locknut (122), slotted washer (123), pulley (121), fan (120) and pulley disc (121) the from the input shaft. nspection 1. Check all components for excessive wear or damage.

  • Page 27: Side Cover

    21 for the required torque ant from the main housing, place a protective values. cover over the internal parts of the transaxle; avoiding any debris from entering the hous- ing. pry point Locating pin pry point Locating pin Stuff a clean rag in the center section oil filter passage before scraping the sealant off the center section. This is to prevent any sealant from getting into the oil passage. figure 19, side Cover ZT-2800 /ZT-3100/ZT-3400™ ®...

  • Page 28: Bull, Pinion And Reduction Gears

    1. Inspect the bull gear (91) – teeth and internal splines, for wear or damage. 2. Separate the reduction gears and inspect the gears and jack shaft pin for excessive wear or damage. Replace if necessary. Motor Shaft (73) figure 20, Bull, reduction and pinion gear ZT-2800 /ZT-3100™/ZT-3400™ ®...

  • Page 29: Charge Pump

    2. Align the mark on the charge pump cover, (from step 1, Disassembly), with the mark on the main housing. Charge Pump Cover Main Housing Mark figure 21a, Charge pump figure 21, Charge pump Cover Orientation (ZT-2800/ZT-3100 shown) ZT-2800 /ZT-3100/ZT-3400™ ®...

  • Page 30: Input Shaft

    NOTE: To assist in the removal of the pump shaft, lightly tap (using a neoprene assembly head hammer) the shaft from the charge pump side of housing. Care 1. Reassemble all parts in the reverse order of disassembly. ZT-3400 ZT-2800/ZT-3100 figure 22, input shaft ZT-2800 /ZT-3100™/ZT-3400™ ®...

  • Page 31: Bypass Arm

    (31) as a single item. NOTE: It is not necessary to remove the clip retaining ring (31) from the bypass rod (32) unless it is damaged or worn. 5. Remove the lip seal (30) and discard. inspection 1. Inspect the bypass rod (32) for wear or dam- age. Replace if necessary. NOTE: Take care to insure that the bypass rod is free of burrs that may cut the rubber lip seal. figure 23, Bypass arm ZT-2800 /ZT-3100/ZT-3400™ ®...

  • Page 32: Swashplate

    1. Inspect the swashplate (40) and thrust bearing assembly (65) for wear or damage. Replace if necessary. 2. Inspect pump block per detail on page 32. Thick Race Toward Pistons figure 25, Hydraulic pump Components figure 24, swash plate ZT-2800 /ZT-3100™/ZT-3400™ ®...

  • Page 33: Center Section

    2. Inspect the motor shaft for wear or damage. Replace if necessary. 3. Inspect for scratches on the machined sur- faces of the center section. 4. Inspect motor cylinder block assembly (64) per detail on page 35. Center Section figure 26, Center section ZT-2800 /ZT-3100/ZT-3400™ ®...

  • Page 34: Brake Assembly

    BraKe asseMBLY (Code 1 or 2) (ZT-2800/ZT-3100) assembly Character #7 in the model number code = 1 or 2. 1. Install the new O-rings (10) onto the brake (cam) shaft (101). Example: ZX-XXXX-1XXX-XXXX NOTE: Apply a thin coating of oil to the O-rings Refer to Figure 27 before installing. disassembly To protect the O-rings from possible damage during installation, apply a 1.

  • Page 35: Brake Assembly

    Z * - (G, H, J) * * * - * (E-H, N-T) * * - * * * * Left Rot. B Z * - (K, L, M) * * * - * (E-H, N-T) * * - * * * * figure 28, Brake shaft assembly figure 29, Brake pawl Orientation ZT-2800 /ZT-3100/ZT-3400™ ®...

  • Page 36: Center Section Kit

    1. Inspect all components for unusual wear or damage. Pay particular attention to the cen- ter section’s threaded ports and passages; there must be no lose particles or debris. Rubber Plug (16) NOTE: For non-charge ZT-2800 units without Solid “charge relief,” a rubber plug (16) will be present rather than connecting tubes (ref. on page 27, Figure 21a). See diagram to the right.

  • Page 37: Check Plugs & Seals

    Insertion Area nents, set aside until ready for installation of the center section and swashplate. Refer to pages 30 and 31. figure 31, plug seal (26) Pistons Piston Seats Springs Cylinder Block figure 32, pump/Motor Cylinder Block assembly ZT-2800 /ZT-3100/ZT-3400™ ®...

  • Page 38: Axle Shaft

    (ZT-2800/ZT-3100) Refer to Figure 33 assembly disassembly 1. Assemble items in reverse order of disas- 1. Remove all items beginning on page 14. sembly. 2. Remove the retaining ring (90). NOTE: To protect the lip seal from possible 3. Remove and discard the lip seal (96).

  • Page 39: Axle Shaft

    6. Remove the axle shaft (94) in the direction of arrow. NOTE: To protect the lip seal from possible damage when installing into the bore 6. Remove the bearing (95). and over the axle shaft, apply a protec- NOTE: Remove the bearing from the axle shaft tive covering over the splines, sharp only if worn or damaged. corners and/or keyway of the axle shaft (e.g., cellophane, tape, etc.). figure 34, axle assembly ZT-2800 /ZT-3100/ZT-3400™ ®...

  • Page 40: Assembly After Complete Tear Down

    11. Perform the purge procedures listed on 6. Install the reduction gears, pinion gear and page 12. bull gear. See page 26. Sealant Path for Main Housing Sealant Path for Center Section figure 35, sealant application diagram ZT-2800 /ZT-3100™/ZT-3400™ ®...

  • Page 41: Side Cover - Screw Tightening Sequence

    COVer – sCrew TigHTening seQUenCe Starting with the number “1” screw location, tighten sequentially through to “16.” Torque each screw to 105 - 155 lb-in (11.87 - 17.52 Nm). NOTE: As a general rule, use the low end of the torque specification. figure 36, screw tightening sequence diagram ZT-2800 /ZT-3100/ZT-3400™ ®...

  • Page 42: How To Use Service Schematic

    To narrow your search in the table, find the character column code that appears as the second character in your model number. In this example it will be “H”. Refer to the model number in step 2. Since character number 2 is “H”, the part number for item 81 is 52148. ZT-2800 /ZT-3100™/ZT-3400™ ®...

  • Page 43: Notes

    ZT-2800 /ZT-3100/ZT-3400™ ®...

  • Page 44: Zt-2800 ® Exploded View & Parts List

    ZT-2800 /ZT-3100™ TransaXLe eXpLOded View ® ZT-2800 /ZT-3100™/ZT-3400™ ®...
  • Page 45 ZT-2800 /ZT-3100™ TransaXLe parTs LisT ® Housing, Main Seal, Lip 25 x 52 x 10 TC (Gray) Cover, Side Plug 9/16-18 (Metal) Nut, Patch Lock 3/4-16 Screw, Hex head 1/4-20 x 1.25” Pawl, Brake O-ring, -111,.103 x .424 Shaft, Brake...

  • Page 46: Zt-3400 Exploded View & Parts List

    ZT-3400 TransaXLe eXpLOded View ZT-2800 /ZT-3100™/ZT-3400™ ®...
  • Page 47 Gear, Reduction (45T or 46T) Kit, Input Shaft Gear, Reduction 11T Kit, RTN Control Arm Pin, Jack Shaft Kit, Axle Shaft Ring, Retaining 2.06 Internal Gear, Bull 54T Spacer .750 x 1.320 x .257 Bearing, Ball .75 x 40 x 12 ZT-2800 /ZT-3100/ZT-3400™ ®...

  • Page 48: 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 transfer of power. Inlet Line: A supply line to the pump. ZT-2800 /ZT-3100™/ZT-3400™ ®...
  • Page 49 System Pressure: The pressure which overcomes the total resistance in a system, including all efficiency losses. Valve: A device which controls fluid flow direction, pressure, or flow rate. Variable Displacement Pump: A pump in which the displacement per revolution can be var- ied. Volumetric Displacement: The volume for one revolution. ZT-2800 /ZT-3100/ZT-3400™ ®...
  • Page 50 ZT-2800 /ZT-3100™/ZT-3400™ ®...
  • Page 51 ZT-2800 /ZT-3100/ZT-3400™ ®...
  • Page 52 © 2011 HYDRO-GEAR Printed in U.S.A. Rev. P12...

This manual is also suitable for:

Zt-3100Zt-3400

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