Related Manuals for Hydro-Gear ZT-3600
Summary of Contents for Hydro-Gear ZT-3600
- Page 1 ZT-2800 /ZT-3100 /ZT-3200™/ZT-3400 ® ® ® Integrated Zero-Turn Transaxle Service and Repair Manual BLN-52441 January 2018...
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Page 2: Table Of Contents
Table Of Contents Foreword ............1 Tear Down and Reassembly......21 Product Identification ........1 How To Use This Manual......21 Description and Operation ......2 General Instructions ........21 Introduction ........... 2 Tools ............22 Hydraulic Schematic ........3 Torques ............ -
Page 3: Foreword
Zero-Turn Transaxles. resenting EETC (Equipment & Engine Training Also included is a glossary of terms that are Council) at (262) 367-6700 or their Hydro-Gear frequently used throughout the industry and in Central Service Distributor. Many distributors Hydro-Gear service publications. Understand- will be hosting certification testing. -
Page 4: Description And Operation
Introduction Both transaxles are fully flooded with oil. A The purpose of this manual is to provide in- common external expansion tank assures the formation useful in servicing the Hydro-Gear ® drives’ cool, quiet operation. An external filter on ZT-2800... -
Page 5: Hydraulic Schematic
HYDRAULIC SCHEMATIC Vent Case Reservoir Input Shaft Bypass Motor Pump Motor Shaft System Check Valves Filter Charge Relief Charge Pump Figure 2, Hydraulic Schematic With Charge Pump Vent Case Reservoir Input Shaft Bypass Motor Pump Motor Shaft System Check Valves Filter Figure 3, Hydraulic Schematic Without Charge Pump (ZT-2800) ZT-2800... -
Page 6: External Features
EXTERNAL FEATURES ZT-2800 /ZT-3100 /ZT-3200 ® ® (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-3200 /ZT-3400... - Page 7 EXTERNAL FEATURES ZT-2800 /ZT-3100 /ZT-3200 ® ® (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) — ZT-2800 ZT-2800 /ZT-3100...
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Page 8: Technical Specifications
TECHNICAL SPECIFICATIONS ZT-2800 ZT-3100 ZT-3200 ® ® SPECIFICATIONS ZH/ZJ ZK/ZL Overall Transaxle 20.69:1 24.74:1 27.23:1 20.69:1 24.74:1 27.23:1 27.23:1 Reductions Pump Displacement 0.61 in /rev [10cc/rev] Motor Displacement 0.97 in /rev [16cc/rev] Input Speeds Maximum Hi-Idle (No Load) 3000 rpm Non-Charge — 3600 rpm Minimum 3600 rpm Charged... -
Page 9: Safety
SAFETY Wear appropriate clothing. Loose or hanging clothing or jewelry can be hazardous. Use the This symbol points out important safety appropriate safety equipment, such as eye and instructions which, if not followed, could en- hearing protection, and safety-toe and slip-proof danger the personal safety and/or property of shoes. -
Page 10: Troubleshooting
TROUBLESHOOTING In many cases, problems with a transaxle are WARNING not related to a defective transaxle, but are caused by slipping drive belts, partially engaged Do not attempt any servicing or ad- bypass valves, and loose or damaged control justments with the engine running. linkages. -
Page 11: Service And Maintenance
Fluids have to be determined by the machine manufacturer/end user due to varying The fluids used in Hydro-Gear products have hose sizes/lengths and expansion tank been carefully selected, and only equivalent, or sizes. better products should be substituted. ZT-2800 /ZT-3100... -
Page 12: Filter And Filter Guard
FILTER AND FILTER GUARD Refer to Figure 4 Assembly Disassembly 1. Reassemble all parts in the reverse order 1. Remove the hex head screws (105), and of disassembly. filter guard (106). 2. When tightening the fasteners, refer to the 2. Remove the filter (23) and discard. table on page 22 for the required torque NOTE: Always replace the filter when perform- values. -
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
PURGING PROCEDURES Due to the effects air has on efficiency in hy- The following procedures are best performed drostatic drive applications, it is critical that it is with the vehicle drive wheels off the ground. purged from the system. Then repeated under normal operating condi- tions. -
Page 15: Return To Neutral Setting
RETURN TO NEUTRAL SETTING WARNING WARNING Do not attempt any servicing or ad- POTENTIAL FOR SERIOUS INJURY justments with the engine running. Inattention to proper safety, operation, or Use extreme caution while inspecting maintenance procedures could result in the drive belt assembly and all vehicle personal injury, or damage to the equip- linkage! ment. -
Page 16: Return To Neutral Assembly
RETURN TO NEUTRAL ASSEMBLY Refer to Figure 8 Assembly Disassembly 1. Reassemble all parts in the reverse order 1. Remove all items previously discussed in of disassembly. their recommended order. 2. When tightening the fasteners, refer to the 2. Remove the RTN control arm kit (211) by table on page 22 for the required torque first removing the spring (147) and Torx values. -
Page 17: Control Arm Assembly
CONTROL ARM ASSEMBLY Refer to Figure 9 Assembly Disassembly 1. Reassemble all parts in the reverse order 1. Remove all items previously discussed in of disassembly with the exception of the their recommended order. washer (45) and the lock nut (47). 2. Remove the lock nut (47), and the washer NOTE: Discard the washer (45) and the (45). -
Page 18: Parking Brake Adjustment
ZT-2800 /ZT-3100 PARKING BRAKE ADJUSTMENT (Code 1 or 2) ® ® Only if Character #7 in the model number 4. While holding the parking brake handle code is 1 or 2. (102) firmly onto the splines, remove clip (103) from the shaft tip. Example: ZX-XXXX-1XXX-XXXX 5. -
Page 19: Parking Brake Assembly
ZT-2800 /ZT-3100 PARKING BRAKE ASSEMBLY (Code 1 or 2) ® ® Only if character #7 in the model number code is 1 or 2. Example: ZX-XXXX-1XXX-XXXX Refer to Figure 12 Inspection Disassembly 1. Inspect all parts for excessive wear or dam- 1. Mark the position of the cam stop retainer age. -
Page 20: Brake Arm Assembly
ZT-2800 /ZT-3100 /ZT-3200 /ZT-3400 BRAKE ARM ASSEMBLY ® ® ® (Code 3/5/6/7) Character #7 in the model number code is 3, 5, 6 or 7. Example: ZX-XXXX-3XXX-XXXX Refer to Figure 13 Inspection Disassembly 1. Inspect all parts for excessive wear or dam- 1. Mark the position of the brake arm (102) in age. -
Page 21: Parking Brake Assembly
ZT-2800 /ZT-3100 PARKING BRAKE ASSEMBLY ® ® Assembly (Code A) 1. Reassemble all parts in the reverse order Character #7 in the model number code is A. of disassembly. See page 22 for the torque Example: ZX-XXXX-AXXX-XXXX values of the brake yoke bolts (176 and 175). -
Page 22: Hub Removal
HUB REMOVAL Do not use this procedure to remove the 4. Insert the hub removal tool over the flange drive wheel from the transaxle. Remove the wheel hub studs. Install lug nuts and secure drive wheel by removing the lug nuts. evenly. -
Page 23: 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 24: Tools
TOOLS RE QUIRED TOOLS Miscellaneous Sockets Hub Puller 1/2”-3/8” Adapter Flat Blade Screw Driver (2) 3/8” Deep Torque Wrench 1-1/8” Deep Air Impact Wrench 1/4” Allen Rubber or Neoprene Mallet 3/4” Deep Breaker Bar 9/16” Deep Side Cutters/Snips T-40 Torx Head Needle Nose Pliers 7/8”... -
Page 25: Transaxle Removal
TRANSAXLE REMOVAL FAN AND PULLEY NOTE: It is necessary to remove the Refer to Figure 16 transaxle from the vehicle before performing the Disassembly repair procedures presented in this section. To remove the wheel from the hub, do so by FAN AND PULLEY KIT (207) CONFIGURATION “A” removing the lug nuts. Do not remove the 1. - Page 26 FAN AND PULLEY (Continued) Refer to Figure 17 Refer to Figure 18 FAN AND PULLEY KIT (207) CONFIGURATION “B” FAN AND PULLEY KIT (207) CONFIGURATION “C” 1. Remove the locknut (122), and detach the 1. Remove the locknut (122) and detach the fan and pulley assembly from the input fan and pulley assembly from the input shaft.
- Page 27 FAN AND PULLEY (Continued) Refer to Figure 19 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.
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Page 28: Side Cover
SIDE COVER Refer to Figure 20 Disassembly Inspection 1. Inspect the bearing and bushing areas in the 1. Remove all external items previously dis- side cover for excessive wear or damage. cussed in their recommended order. Replace if necessary. 2. Remove filter (23) and discard. Drain oil Assembly from transaxle. -
Page 29: Bull, Pinion And Reduction Gears
BULL, PINION AND REDUCTION GEARS Refer to Figure 21 Assembly Disassembly 1. Install the washer (74), pinion gear (72), 1. Remove external items beginning on page and secure their placement with retaining ring (71) onto the motor shaft (73). 2. Remove washer (80) and reduction gear 2. -
Page 30: Charge Pump
CHARGE PUMP Refer to Figures 22-22a Disassembly 3. When tightening the fasteners, refer to the table on page 22 for the required torque 1. Mark the orientation of the charge pump values. cover relative to the main housing, prior NOTE: As a general rule, use the low end of to removal. Refer to figure 21. the torque specification on fasteners 2. -
Page 31: Charge Pump Orientation
CHARGE PUMP ORIENTATION Z*-L***-****-**** Z*-K***-****-**** Z*-P***-****-**** Z*-N***-****-**** Z*-G***-****-**** Z*-H***-****-**** Figure 23, Charge Pump Orientation ZT-2800 /ZT-3100 /ZT-3200 /ZT-3400 ® ® ®... -
Page 32: Input Shaft
INPUT SHAFT Refer to Figure 24 Disassembly should be taken not to damage the shaft or gerotor running surface. 1. Requires removal of all items beginning on Remove the bearing from pump shaft page 14. only if worn or damaged. 2. Remove the retaining ring (57). 5. Remove the wire ring retainer (54) and the 3. Remove the lip seal (56) and discard. bearing (53) from the pump shaft (52). -
Page 33: Bypass Arm
BYPASS ARM Refer to Figure 25 Assembly Disassembly 1. Install a new lip seal (30). 1. Requires removal of all items beginning on page 14. 2. Install the clip retaining ring (31) and bypass rod (32). 2. Remove the push-on retaining ring (35) and discard. -
Page 34: Swashplate
SWASHPLATE Refer to Figures 26-27 Assembly Disassembly 1. Reassemble all parts in the reverse order 1. Requires removal of all items beginning on of disassembly. page 14. 2. Apply a light coating of oil to running sur- 2. Remove the swashplate (40) and pump faces on center section, swashplate bearing cylinder block assembly (69) as a single races, thrust bearing assembly and pump... -
Page 35: Center Section
CENTER SECTION Refer to Figure 28 Assembly Disassembly 1. Reassemble all parts in the reverse order 1. Requires removal of all items beginning on of disassembly. page 14. 2. Apply a light coating of oil to all running 2. Remove the center section mounting screws surfaces on the center section. -
Page 36: 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 29 before installing. Disassembly To protect the O-rings from possible damage during installation, apply a 1. - Page 37 BRAKE ASSEMBLY (Code 3) Assembly Character #7 in the model number code = 3 1. If removed, install brake pawl on brake shaft. Refer to figure 29 for orientation Example: ZX-XXXX-3XXX-XXXX NOTE: Apply a thin coating of oil to the O-rings Refer to Figure 30-31 before installing. Disassembly To protect the O-rings from possible damage during installation, apply a 1. Remove the center section per detail on protective covering over the splines of page 31.
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Page 38: Center Section Kit
CENTER SECTION KIT Refer to Figure 32 Assembly Disassembly 1. Install the charge relief kit (202). Beginning 1. Remove the bypass plate (22) from the with the ball, then the spring, followed by, center section. the cross pin. 2. Remove the plug seals (26) and discard. 2. -
Page 39: Check Plugs & Seals
CHECK PLUGS & SEALS CYLINDER BLOCKS Refer to Figure 33 Refer to Figure 34 In order to gain access to the check plugs (24 Inspect each component of the cylinder block & 25), it is necessary to remove the plug seals assemblies for wear or damage. Inspect the (26). -
Page 40: Axle Shaft
AXLE SHAFT (ZT-2800 /ZT-3100 ® ® Refer to Figure 35 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. - Page 41 AXLE SHAFT (ZT-3200 /ZT-3400 ® Refer to Figure 36 Inspection Disassembly 1. Inspect the splines on the axle shaft for wear 1. Remove all items beginning on page 14. or damage. Replace if necessary. 2. Remove the axle tube (165). 2. Inspect the bearing (95) for wear or damage. 3.
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Page 42: Assembly After Complete Tear Down
ASSEMBLY AFTER A COMPLETE TEAR DOWN If the unit has been torn down completely, the 7. Apply sealant to the main housing and cen- following summary identifies the assembly pro- ter section prior to installing the side cover. cedures necessary to completely assemble the See page 25 and diagram below. -
Page 43: Side Cover - Screw Tightening Sequence
SIDE 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 38, Screw tightening sequence diagram ZT-2800 /ZT-3100 /ZT-3200 /ZT-3400... -
Page 44: How To Use Service Schematic
HOW TO USE THE SERVICE SCHEMATIC (Online) 1. Locate the transaxle model number located on the transaxle. Refer to page 6. 2. Become familiar with the model number code by associating model number code characters to component parts/unit attributes. See example below: Model No. -
Page 45: Notes
NOTES ZT-2800 /ZT-3100 /ZT-3200 /ZT-3400 ® ® ®... -
Page 46: Zt-2800 ® Exploded View & Parts List
ZT-2800 /ZT-3100 /ZT-3200 TRANSAXLE EXPLODED VIEW ® ® ZT-2800 /ZT-3100 /ZT-3200 /ZT-3400 ® ® ®... - Page 47 ZT-2800 /ZT-3100 /ZT-3200 TRANSAXLE PARTS LIST ® ® Housing, Main Cover, Side Nut, Patch Lock 3/4-16 Plug 9/16-18 (Metal) Pawl, Brake Screw, Hex head 1/4-20 x 1.25” Shaft, Brake O-ring, -111,.103 x .424 Handle, Brake Plug, 9/16-18 (Metal) Clip, Retaining Sealant (Loctite 5900) Screw, Hex Flange Head 1/4-20 x .75 Oil, 20W50...
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Page 48: Zt-3400 ® Exploded View & Parts List
ZT-3400 TRANSAXLE EXPLODED VIEW ® ZT-2800 /ZT-3100 /ZT-3200 /ZT-3400 ® ® ®... - Page 49 ZT-3400 TRANSAXLE PARTS LIST ® Housing, Main Shaft, Axle Cover, Side Bearing, Ball Plug 9/16-18 (Metal) Seal, Lip Screw, Hex head 1/4-20 x 1.25” O-ring, -111,.103 x .424 Nut, Patch Lock 3/4-16 Plug, 9/16-18 (Metal) Pawl, Brake Sealant (Loctite 5900) Shaft, Brake Oil, 20W50 Handle, Brake...
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Page 50: Glossary Of Terms
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). Bypass Valve: A valve whose primary function is to open a path for the fluid to bypass the motor or pump. - Page 51 Integrated Zero-Turn Transaxle: 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.
- Page 52 © 2015 HYDRO-GEAR Printed in U.S.A. BLN-52441_P19...
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