ZT-2800 Service Manual
Contents
1. Return To Neutral Assembly Q O E O oo all Q Charge Pump Outboard View Right Return To Neutral Control Z1 28009 TECHNICAL SPECIFICATIONS ZT 2800 TECHNICAL SPECIFICATIONS Overall Transaxle Reduction 20 69 1 24 74 1 27 23 1 Input Speeds Maximum Hi ldle No Load 3000 rpm Non Charge 3600 rpm Charged Minimum 1800 rpm Output Torque Intermittent 300 Ib ft 406 N m 340 Ib ft 461 N m 370 Ib ft 502 N m Continuous 160 Ib ft 217 N m 180 Ib ft 244 N m 200 Ib ft 270 N m Weight on Tires per unit Maximum with 18 tires 400 Ib 181 kg 480 Ib 217 kg 540 Ib 244 kg Maximum with 20 tires 360 Ib 163 kg 440 Ib 199 kg 480 Ib 217 kg Maximum with 22 tires 400 Ib 181 kg 440 Ib 199 kg Axle Shaft Diameter 1 00 in 25 4 mm Axle Shaft End Options Tapered 4 Bolt Flange Parking Brake Type Internal Weight of Unit 32 Ib 14 5 kg PRODUCT IDENTIFICATION The model and configuration of the ZT 2800 can be determined from the label shown below HYDRO GEAR S EHE HHE SIS 7H KCEE 1B8C 1BXX ZH KCEE 1B8c 1BXx Me ou 186 B4 476 Assembled in USA Yea2. Figure 35 Screw tightening sequence diagram 38 ZT 2800 HOW TO USE THE ZT 2800 SERVICE SCHEMATIC Online or Schematic CD 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 e EE S E RES E s pude wx 2 Sepe e Series Reduction Axle Side Axle End Control Control Bypass Fan amp Breather Reserved Ratio amp Pin amp Charge Studs amp ide Side amp Arm Arm Fittings ion Material Pump Length 5 Rotation amp Type i Rotation B 3 On page 1 of the ZT 2800 service schematic locate the part item number that you want to find the part number for In this example we ll use item number 81 Gear 4 Proceed through the schematic pages until you see an illustration of the part 5 Match the item number on the illustrated part to the item number listed in the part attribute table s on the page Notice that 81 is listed several times in this table REDUCTION RATIO CHAR 2 I TEM COMPONENT DESCRIPTION QTY H 72 52149 GEAR 16 81 52148 GEAR 43T 1 lt 72 52344 GEAR 8 52148 GEAR 72 52109 8 52110 72 52541 GEAR GEAR GEAR GEAR 8 52110 72 52342 8 52343
3. 6 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 7 Since character number 2 is H the part number for item 81 is 52148 Z1 28009 39 7 2800 TRANSAXLE EXPLODED VIEW 5 002 u pepnpou SHed Jeind qnH 602 IN 1895 ooz 20 0 OSMOZ 10 L NMOHS LON SW3J ZT 2800 40 7 2800 TRANSAXLE PARTS LIST Housing Main Cover Side Plug 9 16 18 Metal 7 Screw Hex head 1 4 20 x 1 25 10 O ring 111 103 x 424 11 Plug 9 16 18 Metal 13 Sealant Loctite 5900 14 Oil 20W50 20 Center Section 22 Plate Bypass 23 Filter Oil 24 Check Plug Shock Valve 25 Check Plug Shock Valve 26 Seal Plug 1 250 x 250 27 Bolt Center Section 3 8 16 x 1 5 patch 30 Seal Lip 375 x 75 x 25 31 Ring Retaining 375 External 32 Rod Bypass 33 Ring Retaining 750 Internal 34 Arm Bypass 35 Ring Retaining 375 External 40 Trunnion Swashplate 41 Seal Lip 18 x 32x 7 42 Stud Short 5 16 24 43 Puck Friction 44 Arm Control 45 Washer 34 x 88 x 06 46 Screw Torx 5 16 24 x 1 00 patch 47 Nut Hex Lock 5 16 24 UNF 52 Shaft Input 53 Bearing Ball 17x40x12 Open 6203 54 Ring Retaining Wire 561 1 0 55 Washer 1 23 x 1 56 x 04 56 Seal Lip 17
4. 42 43 i 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 custom ers and the industry as a world class supplier and the quality leader in everything we do This Service and Repair Manual is designed to provide information useful in servicing and troubleshooting the Hydro Gear ZT 28009 Integrated Zero Turn Transaxle Also included is a glossary of terms that are frequently used throughout the industry and in Hydro Gear service publications Understand ing terminology is very important It is necessary and a good shop practice that your service area be equipped with the proper tools and the mechanics be supplied the latest information available All repair procedures illustrated in this guide are suggested but pre ferred methods of repair Z1 28009 Internal repair procedures require that the transaxle unit be removed from the vehicle 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 rep resenting EETC Equipment amp Engine Training Council at 262 367 6700 or their Hydro Gear Central Service Distributor Many distributors will be hosting certification testing These study guides will cover most of the products an
5. 1 M A D J M M E H xs dale L 29 Brake Pawl Orientation Figure 28 Brake Shaft Assembly Fi igure Z1 28009 33 CENTER SECTION KIT Refer to Figure 30 Disassembly Assembly 1 Remove the bypass plate 22 from the 1 Install the charge relief kit 202 Beginning center section with the ball then the spring followed by the cross 2 Remove the plug seals 26 and discard Refer to figure 31 on page 35 2 Install the new check plugs 24 and 25 in their proper ports IMPORTANT Before removing the check plugs it is important to note their specific loca 3 Install the new plug seals 26 tion i e check plug 24 needs to be reinstalled in the same port it was removed from and the same for check plug 25 After removing the check plugs inspect for debris or damage 4 Install the bypass plate 22 Applying a very small film of grease on the bypass plate will help secure it in the center section 3 Remove the check plugs 24 and 25 and inspect Refer to Check Plugs amp Seals page 35 Charge Relief Kit 4 Remove the pin spring and ball that make up the charge relief kit 202 Depressing the charge spring with the clean flat side of a slotted screw driver will allow the pin to slide out Use caution when relieving spring force Inspect the center section at the charge seat for wear or damage 202 NOTE
6. 71 onto the motor shaft 73 Install the washer 70 onto the motor shaft 73 Install the bull gear 91 onto the axle 94 Install the jack shaft pin 83 washer 80 reduction gears 82 and 81 Install washer 80 to jack shaft pin 83 Motor Shaft 73 Figure 20 Bull Reduction and Pinion Gear ZT 2800 CHARGE PUMP Refer to Figures 21 21a Disassembly 1 Mark the orientation of the charge pump cover relative to the main housing prior to removal Refer to figure 21 2 Remove the hex head screws 134 charge pump cover gerotor assembly and the O ring 132 Remove the connecting tubes 130 atthis point only if the center section will be removed A pick type tool can be used to remove the connection tubes Inspection 1 Inspect the gerotor assembly for wear or damage Replace if necessary Assembly 1 Reassemble all parts in the reverse order of disassembly NOTE When reinstalling the charge pump components replace the O ring 132 Also replace the connecting tubes 130 if they have been removed 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 I OC Mark Figure 21 Charge Pump Cover Orientation Z1 28009 3 When tightening the fasteners refer to the table on page 21 for the required torque values NOTE As a general rule use the low e
7. Fluid Volume and Level Fluid volume information is provided in the table below Total system volume will de pend on expansion tank size hose length and transaxle volume Certain situations may require additional fluid to be added or even replaced Refer to page 10 and figure 5 for the proper fill port location Recheck the fluid level once the unit has been operated for approximately 1 minute Purging will be required if oil has been changed Refer to the purging procedures on page 12 Fluid Description 20W50 engine oil Volume 2284 ml 77 23 fl oz 40 82 ml 1 35 2 77 fl oz 38 60 ml 1 31 fl oz ft Component Transaxle bottom of fill port Expansion Tank cold fill line Hose 0 5 I D FILTER AND FILTER GUARD Refer to Figure 4 Disassembly Assembly 1 Remove the hex head screws 105 and 1 Reassemble all parts the reverse order filter guard 106 of disassembly 2 Remove the filter 23 and discard 2 When tightening the fasteners refer to the table on page 21 for the required torque NOTE Always replace the filter when perform ing any internal maintenance to the transaxle 3 Filltransaxle with oil Refer to Fluid Change Procedures page 11 steps 3 and 4 for filter change instructions values 3 Remove the metal oil drain plug 5 or the fitting 111 from inlet port and allow any remaining oil to drain from the transaxle NOTE As a general rule use the low end of t
8. O HYDRO GEAR ORWARD MOTION THROUGH FORWARD THINKING ZT 2800 Integrated Zero Turn Transaxle Service and Repair Manual BLN 52441 D ber 2008 Table Of Contents Foreword DL 1 Description and Operation 2 I tred uctlien u u T er 2 Hydraulic 3 External Features 0 4 Technical Specifications 6 Product Identification 6 Safe ly etcetera esce oiseau 7 Personal Safety 7 Tool Safety 7 Work Area Safety 7 Servicing Safety 7 Troubleshooting 8 Service and Maintenance 9 External 9 Service and Maintenance Procedures 9 P lle 9 Fluid Volume and Level sasnnneeeeeeeee 9 Filter and Filter Guard 10 Fluid Change Procedure 11 Purging Procedures 12 Return To Neutral Setting 13 Return To Neutral Assembly 14 Control Arm Assembly 15 Parkin
9. The check ball should seat properly in the check seat 26 Inspection 1 20 1 Inspect all components for unusual wear or Figure ior Center Sect on 201 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 relief a rubber plug 16 will be present NOTE For non charge units without charge rather than connecting tubes ref CX page 27 Figure 21a See diagram to the right Center Section Non Charge 34 ZT 2800 CHECK PLUGS amp SEALS Refer to Figure 31 In order to gain access to the check plugs 24 amp 25 itis necessary to remove the plug seals 26 This is accomplished by inserting a seal hook or puller into and through one of the insertion points rectangular recesses on the plug seal refer to figure 31 After successfully removing the plug seals discard and replace with new seals 4 Insertion Area Figure 31 Plug Seal 26 ZT 2800 CYLINDER BLOCKS Refer to Figure 32 Inspect each component of the cylinder block assemblies for wear or damage Inspect the cylinder block s running surface for scratches or galling Replace if necessary NOTE During separation of the cylinder blocks take care not to damage the surfaces of the pistons and block Apply a thin coating of oil to all compo nents of the cylinder block assemblies before reassembly A
10. 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 contami nants 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 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 Z1 28009 43 NOTES A4 ZT 2800 NOTES Z1 28009 45 HYDRO GEAR EETC 2008 HYDRO GEAR inted in U S A v P5 e g r
11. the equipment or the performance of your job Never allow untrained or unauthorized person nel to service or repair the equipment Z1 28009 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 slip proof 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 ex tension 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 capa bility 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 materi
12. 20 and pulley disc 121 the from the input shaft Inspection 1 Check all components for excessive wear or damage Replace if necessary 2 Inspect input shaft splines for wear or dam age Assembly 1 Reassemble all parts the reverse order of disassembly 2 When tightening the fasteners refer to the table on page 21 for the required torque values NOTE As a general rule use the low end of the torque specification on fasteners when reassembling the unit amp 122 Figure 18 Fan Pulley Kit 207 Configuration D 24 ZT 2800 SIDE COVER Refer to Figure 19 Disassembly 1 Remove all external items previously dis cussed in their recommended order Remove filter 23 and discard Drain oil from transaxle Refer to page 11 Remove the screws 7 separate side cover 2 from main housing 1 using pry points as required Remove the bearing 93 from side cover 2 Remove the spacer 92 from axle 94 Clean off all the old sealant from the cover 2 and the main housing 1 Take care not to damage the sealing surfaces A wire brush and solvent is effective IMPORTANT Before scraping the old seal ant from the main housing place a protective cover over the internal parts of the transaxle avoiding any debris from entering the hous ing Pry Point Inspection 1 Inspectthe bearing and bushing areas in the side cover for excessive wear or dama
13. NOTE Only remove the seal 41 if damaged reassembling the unit or worn The seal cannot be serviced separately Refer to Seal Kit in the Items List on page 41 Inspection 1 Inspect all parts for excessive wear or dam age Replace if necessary Figure 9 Control Arm Assembly Z1 28009 15 PARKING BRAKE ADJUSTMENT Code 1 or 2 Character 7 in the model number code 1 Or 2 Example ZX XXXX 1XXX XXXX WARNING POTENTIAL FOR SERIOUS INJURY When servicing the parking brake on unlevel terrain it is essential to chock the vehicle wheels to prevent vehicle movement It should not be necessary to adjust the transaxle parking brake over the life of the vehicle In the event that the transaxle parking brake does not hold per vehicle manufacturer s specifications the parking brake can be adjusted by rotating the handle 102 1 16 Brake Cam Shaft 101 Note orientation of the vehicle parking brake and linkage in the activated locked posi tion Disengage the brake Detach the vehicle parking brake linkage from the parking brake handle 102 Brake Handle 102 Reference Mark Figure 10 Brake Handle Orientation 4 While holding the parking brake handle 102 firmly onto the splines remove clip 103 from the shaft tip Before removing the parking brake handle 102 scribe a reference mark between the handle and shaft tip 101 Remove the brake handle 102 f
14. Screw Hex Head 1 4 20 x 75 111 Fitting STR 9 16 18 SAE 122 Nut Hex Locking 1 2 20 Nylon 123 Screw Hex Head 134 HFHCS 1 4 20 x 75 142 SHCS 5 16 24 x 1 Patch 142 Stud 5 16 24 Friction Pack Torque 180 240 Ib in 20 3 27 1 Nm 105 155 Ib in 11 8 17 5 Nm 180 240 Ib in 20 3 27 1 Nm 130 150 Ib in 14 7 16 9 Nm 280 400 Ib in 31 6 45 2 Nm 280 400 Ib in 31 6 45 2 Nm 525 700 Ib in 59 3 79 1 Nm 50 120 Ib in 5 6 13 5 Nm 230 310 Ib in 25 9 35 0 Nm 85 120 Ib in 9 6 13 5 Nm 180 200 Ib ft 244 271 Nm 65 95 Ib in 7 3 10 7 Nm 180 240 Ib in 20 3 27 1 Nm 360 520 Ib in 40 6 58 7 Nm 50 80 Ib in 5 6 9 0 Nm 65 95 Ib in 7 3 10 7 Nm 175 200 Ib in 19 7 22 6 Nm 50 65 Ib in 5 6 7 3 Nm Operation Oil Input Port Side Cover Screws Side Cover Oil Level Port Oil Filter Center Section Center Section Center Section Screws Control Arm RTN FR Control Arm Control Arm Short Stud Hub Nut Filter Guard Screws Breather Fitting Fan to Input Shaft Nut Fan to Pulley Assembly Charge Plate Screws Neutral Arm Screw Friction Pack Stud As a general rule use the low end of the torque spec on fasteners when reassembling the unit Z1 28009 21 TRANSAXLE REMOVAL NOTE It is necessary to remove the ZT 2800 from the vehicle before performing the repair procedures presented in this section To remove the wheel
15. a tendency to separate from the liquid phase Gerotor A formed rotor set operating about an eccentric that provides a fixed displacement for pumps or motors Hydraulic Motor device which converts hydraulic fluid power into mechanical force and mo tion 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 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 42 ZT 2800 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 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
16. age reference NOTE Prior to applying the new sealant the old sealant must be removed from all The part reference numbers provided in each surfaces assembly procedure are keyed to the individual exploded views and are also keyed to the com plete unit exploded view on page 40 A small consistent bead approx 1 16 1 8 inch of the sealant around the housing face will be sufficient Use 1 Install the axle shaft See page 36 sparingly 2 Install the hydraulic components See pages The illustration below indicates the cor 30 35 rect sealant path 3 Install the bypass rod and arm See page 8 Install the RTN assembly See page 14 29 9 Install the transaxle onto the vehicle 4 install theinputshart 28 liste ing Hp OBnlalE ee 10 Install new oil filter and fill the transaxle with 5 Install the charge pump See page 27 new oil See pages 9 and 10 6 Install the reduction gears pinion gear and 11 Perform the purge procedures listed on bull gear See page 26 page 12 Sealant Path for Main Housing oQ 2 Sealant Path for Center Section Figure 34 Sealant Application Diagram Z1 28009 37 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
17. al in the appropri ate containers TROUBLESHOOTING In many cases problems with the ZT 28009 WARNING 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 Service and Maintenance before assuming the transaxle is malfunctioning The table below provides a Follow all safety procedures outlined in troubleshooting checklist to help determine the the vehicle owner s manual cause of operational problems Do not attempt any servicing or ad justments with the engine running Use extreme caution while inspecting the drive belt assembly and all vehicle linkage TROUBLESHOOTING CHECKLIST Possible Cause Corrective Action Control linkage bent or out of adjustment Repair or replace linkage Page 9 Drive belt slipping or pulley damaged Repair or replace drive belt or pulley Page 9 Vehicle tires improperly inflated Refer to vehicle manufacturer suggested pressure Control linkage bent or out of adjustment Repair or replace linkage Pages 9 and 13 Bypass assembly sticking Repair or replace bypass Page 29 Brake Partially Engaged Disengage Brake Replace Broken or Missing Brake Return Spring nits Noisy Oil level low or contaminated oil Fill to proper level or change oil Page 11 Excessive loading Reduce vehicle loading Page 9 Loose parts Repair or replace loose par
18. ar enough to rotate the handle one tooth in the angular direction opposite the brake handle s actu ated position Attach the retaining clip 103 to the brake cam shaft Connect the vehicle parking brake linkage to the brake handle 102 Test the parking brake to assure it meets the vehicle manufacturer s specifications 10 It is also important to assure that the park ing brake is not partially engaged while the vehicle is in the normal drive mode This can be confirmed by moving the vehicle to level ground turning the engine off disen gaging the brake engaging the bypass and assuring that the vehicle can be moved by pushing with reasonable effort Clip 103 Brake Handle 102 Figure 11 Brake Handle Removal ZT 2800 PARKING BRAKE ASSEMBLY Code 1 or 2 Character 7 in the model number code 1 Inspection or 2 1 Inspect all parts for excessive wear or dam Example ZX XXXX 1XXX XXXX age Replace if necessary Refer to Figure 12 2 Inspectthe splines on the handle and brake cam shaft Disassembl y Assembly 1 Mark the position of the cam stop retainer 104 in relation to the side cover 2 1 Reassemble all parts the reverse order of disassembly NOTE The orientation of the cam stop and brake cam to one another is very im portant Indicate their relationship to each other on the side cover to assist in their correct assembly See Insert NOTE As a general rule use the lo
19. center section swashplate bearing races thrust bearing assembly and pump block assembly 3 Place the thrust bearing assembly 65 into swashplate 40 such that the thick race of the bearing assembly faces out With the piston facing the thrust bearing place the pump block assembly 69 into the swashplate While pressing the pump block assembly thrust bearing pump cylinder block and swashplate together align to center section in main housing Toward Pistons 7 Y Thick Race Figure 25 Hydraulic Pump Components ZT 2800 CENTER SECTION Refer to Figure 26 Disassembly Assembly 1 Requires removal of all items beginning on 1 Reassemble all parts in the reverse order page 22 of disassembly 2 Remove the center section mounting screws 2 Apply a light coating of oil to all running 27 surfaces on the center section Remove the center section the motor shaft 3 Place the thrust bearing assembly 60 into 73 the motor cylinder block assembly 64 the main housing 1 and the brake shaft 101 as a single item t EU 4 Place the motor shaft 73 into the center Remove the motor cylinder thrust bearing section Slide the motor block assembly 64 60 onto the motor shaft 73 so that the pistons are facing the thrust bearing 60 Remove the motor cylinder block assembly 64 from the motor shaft 73 Removethe 5 Install the brake shaft assembly 101 if not motor shaft 73 from th
20. d manufacturers in our industry For more information about Hydro Gear or our products please contact your Central Service Distributor or call our Customer Service Depart ment at 217 728 2581 DESCRIPTION AND OPERATION Introduction The purpose of this manual is to provide in formation useful in servicing the Hydro Gear ZT 2800 Integrated Zero Turn Transaxle This manual includes the ZT 2800 s general descriptions hydraulic schematics technical specifications servicing and troubleshooting procedures Other than recommended oil and filter changes the transaxle normally will not require servic ing 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 Do not wash the transaxle while it is hot Do not use a pressure washer to clean the unit General Description The ZT 2800 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 dis placement of 16cc per revolution The vari able displacement pump features a trunnion mounted swashplate with a direct proportional displacement control Reversing the direction of the swashplat
21. e cam shaft 101 and cam shaft 101 Install the brake cam kit the brake puck 100 208 in center section Refer to Figure 27 1 Remove the center section per detail on page 31 3 Remove the O rings 10 from the brake cam shaft 101 and discard Inspection 1 Inspect all components for unusual wear or damage Center Section Figure 27 Brake Cam Kit 32 ZT 2800 BRAKE ASSEMBLY Code 3 Character 7 in the model number code 3 Assembly 1 Ifremoved install brake pawl on brake shaft Example ZX XXXX 3XXX XXXX Refer to figure 29 for orientation Refer to Figure 28 NOTE Apply a thin coating of oil to the O rings before installing Disassembly To protect the O rings from possible 1 Remove the center section per detail on damage during installation apply a page 31 protective covering over the splines of the brake shaft e g cellophane tape NOTE Take note of the orientation of the brake etc pawl 100 and the brake shaft 101 2 Install the new O rings 10 onto the brake 2 Remove the brake shaft 101 and the brake shaft 101 pawl 100 3 Remove the O rings 10 from the brake Lb shaft 101 and discard the O rings MS 4 Remove the brake pawl from the brake shaft gt if pawl shaft or splines are damaged 5 SS Inspection 2 1 Inspect all components for unusual wear Eet damage Center Section J 9 2
22. e ZT 28009 should include the following 1 Checkthe vehicle operator s manual for the recommended load ratings Insure that the current application does not exceed load rating 2 Check oil level in accordance with Fluid Change Procedure step 12 Refer to page 11 3 Inspectthe vehicle drive belt dier pulley s and idler spring s Insure that no belt slip page can occur Slippage can cause low input speed to the transaxle 4 Inspect the vehicle control linkage to the directional control arm on the transaxle Also insure that the control arm is securely fas tened to the trunnion arm of the transaxle 5 Inspect the bypass mechanism on the transaxle and the vehicle linkage to insure that both actuate and release fully Service and Maintenance Proce dures Some of the service procedures presented on the following pages can be performed while the ZT 2800 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 Fluids The fluids used in Hydro Gear products have been carefully selected and only equivalent or better products should be substituted Z1 28009 Typically an engine oil with a minimum rating of 9 0 cSt 55 SUS at 230 F 110 C and an API classification of SL is recommended A 20W50 engine oil has been selected for use by the factory and is recommended for normal operating procedures
23. e center section already installed Refer to figures 27 28 pages 32 33 NOTE A bypass puck is located beneath the motor cylinder block assembly See 6 Align the assembled components center item 22 page 34 section the motor block and shaft and the brake shaft assembly with the main housing 6 Remove brake shaft assembly 101 and and install set aside Refer to figures 27 28 pages 32 33 7 Install the center section mounting screws 27 to the proper torque Inspection 1 Inspect the motor shaft for wear or damage Inspect for scratches on the machined sur Inspect motor cylinder block assembly 64 Inspect the races of the thrust bearing 60 for wear or damage Replace if necessary faces of the center section per detail on page 35 104 Center Section 27 Figure 26 Center Section Z1 28009 31 BRAKE ASSEMBLY Code 1 or 2 Character 7 in the model number code 1 Assembly or 2 1 Install the new O rings 10 onto the brake Example ZX XXXX 1XXX XXXX cam shaft 101 NOTE Apply a thin coating of oil to the O rings before installing Disassembly To protect the O rings from possible damage during installation apply a protective covering over the splines of the brake cam e g cellophane tape NOTE Take note of the orientation of the brake etc 101 th k k 100 cam TOT anc brake 100 2 the brake puck 100 oft the brake 2 Remove the brak
24. e new filter by hand turn 3 4 to one full turn after the filter gasket contacts the filter base surface 5 Re install the filter guard with three 1 4 screws Torque screws to 65 in lbs 7 3 Nm each 6 Repeat steps 1 5 on the opposite side Guard Removed For Visual Clarity Figure 5 Filter Location Z1 28009 transaxle drive 7T Drain old oil filters of all free flowing oil prior to disposal Place used oil in appropriate containers and deliver to an approved re cycling collection facility 8 Remove the top port plug figure 6 from the left side and right side transaxles prior to filling with oil This will allow the transaxles to vent during oil fill 9 Remove the cap from the transaxle s expan sion tank located on the vehicle frame 10 Fill with 20W50 motor oil until oil just ap pears at the bottom of each transaxle s top port approximately 2 qts per transaxle 4 qts total Install the top port plug into each transaxle as the oil level reaches this port 11 Install and torque the top port plugs to 180 in Ibs 20 3 Nm 12 Continue to fill the transaxles through the expansion tank until the Full Cold line
25. e 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 ZT 2800 transaxle is fully flooded with oil A common external expansion tank assures the drives cool quiet operation An external filter provides ease of access for oil maintenance of the drive for the estate and entry level profes 2 sional vehicles The ZT 2800 is designed for both charged and uncharged product versions In the uncharged consumer vehicle drive fluid passes through the filter by interaction of the positive head on the fluid from a properly el evated expansion tank and the negative pres sure created at the pump inlet during piston operation Hydro Gear s patented charge configuration is used in the estate professional version Here fluid is drawn from the case and through the filler and into a fixed displacement gerotor pump Charge pump flow not used to feed the low pressure side of the system is passed over a charge relief valve and back into the transaxle case The check valves in the center section are used to control the make up flow of the fluid to the low pressure side of the loop The ZT 2800 has an internal cog style parking brake It is essential to fully disengage the brake prior to operation A cam style block lifting bypass is utiliz
26. ed in the ZT 2800 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 brake must be disengaged prior to actuating the by pass mechanism 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 ZT 2800 HYDRAULIC SCHEMATIC Case Reservoir Input Shaft X Bypass Motor Shaft 1 Se A p 1 e System Check Valves Filter d Ce Charge Pump Figure 1 Hydraulic Schematic With Charge Pump Vent Case Reservoir Bypass System Check Valves Filter Figure 2 Hydraulic Schematic Without Charge Pump Z1 28009 3 EXTERNAL FEATURES ZT 2800 Axle Shaft Parking Brake Shaft Main Housing Bypass Arm Control Arm Top View Drain Port For Horizontal Installation Top Port Plug Q Q O Parking Brake Am Side Cover Q q A 5 2 Q Inboard View 4 ZT 2800 EXTERNAL FEATURES ZT 2800 Input Shaft Axle Shaft O Oil Filter Expansion Port For Horizontal Installation Outboard View Left Standard Control Fan and Pulley Kit
27. from the hub do so by removing the lug nuts Do not remove the axle hub nut unless replacing the hub the axle seal or removing the axle shaft Before starting any disassembly make certain that your work area is neat and clean Clean the external parts of the transaxle The following procedures are presented in the order recommended for a complete tear down of the transaxle Do not disassemble the unit any farther than necessary to accomplish the required repairs 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 37 FAN AND PULLEY Refer to Figure 15 Disassembly FAN AND PULLEY KIT 207 CONFIGURATION A 1 Remove the locknut 122 slotted washer 123 fan 120 and the pulley 121 from the input shaft Inspection 1 Check all components for excessive wear or damage Replace if necessary 2 Inspect input shaft splines for wear or dam age Assembly 1 Reassemble all parts in the reverse order of disassembly 2 When tightening the fasteners refer to the table on page 21 for the required torque values 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 22 ZT 2800 FAN AND PULLEY Continued Refer
28. fter reassembling the cylinder block compo nents set aside until ready for installation of the center section and swashplate Refer to pages 30 and 31 Pistons Piston Seats Springs Cylinder Block Figure 32 Pump Motor Cylinder Block Assembly 35 AXLE SHAFT Refer to Figure 33 Disassembly Assembly 1 Remove all items beginning on page 22 1 Assemble items in reverse order of disas EE sembly Remove the retaining ring 90 NOTE To protect the lip seal from possible 2 3 Remove and discard the lip seal 96 damage when installing into the bore 4 Remove the axle shaft 94 in the direction and over the axle shaft apply a protec of arrow tive covering over the splines sharp corners and or keyway of the axle shaft 5 Remove the bearing 95 e g cellophane tape etc NOTE Remove the bearing from the axle shaft only if worn or damaged Inspection 1 Inspect the splines on the axle shaft for wear or damage Replace if necessary 2 Inspect the bearing 95 for wear or damage Replace if necessary Figure 33 Axle Assembly 36 ZT 2800 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 unit Each assembly procedure is located by a p
29. g Brake Adjustment 16 Parking Brake Assembly 17 Brake Arm Assembly 18 Z1 28009 Hub Removal 19 Tear Down and Reassembly 20 How To Use This Manual 20 General Instructions 20 dre DEC ce acte 21 Terqu eS 21 Transaxle 22 Fan and Pulley 22 24 Side 25 Bull and Reduction Gears 26 Charge Pump pp 27 Input Shaft 28 Bypass Arm 29 Swashplate 30 Center Section 31 Brake Assembly 32 33 Center Section Kit 34 Check Plugs amp 35 Cylinder Blocks 35 Axle Shaft et ou tees 36 Assembly After Complete Tear Down 37 Side Cover Screw Tightening Sequence 38 How To Use Service Schematic 39 ZT 2800 Transaxle Exploded View 40 2 2800 Transaxle Parts List 41 Glossary Of Terms
30. ge Replace if necessary Assembly 1 Apply a bead of sealant around the perim eter of the main housing face See Sealant Application Diagram on page 37 Install the locating pins if not already in stalled Install the side housing 2 Use care not to smear the sealant bead Install the side housing screws 7 Refer to the screw tightening pattern on page 38 When tightening the fasteners refer to the table on page 21 for the required torque values 4 Stuff a clean rag in the center section oil filler 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 Z1 28009 25 BULL PINION AND REDUCTION GEARS Refer to Figure 20 Disassembly 1 4 Remove external items beginning on page 22 Remove washer 80 and reduction gear set 81 82 as an assembly and set aside Remove second washer 80 and jack shaft pin 83 Remove the washer 70 retaining ring 7 1 pinion gear 72 and washer 74 from the motor shaft 73 Remove the bull gear 91 Inspection 1 26 Inspect the bull gear 91 teeth and internal splines for wear or damage Separate the reduction gears and inspect the gears and jack shaft pin for excessive wear or damage Replace if necessary Assembly 1 Install the washer 74 pinion gear 72 and secure their placement with retaining ring
31. ged hub and replace with a new flanged hub Referto the appropriate manual schemat ics for parts repair procedures and proper torque during reassembly of the flanged hub to the tapered axle Install wheel and rim and torque lug nuts Reference applicable vehicle service man ual for proper lug nut torque Lower the vehicle to the ground remove chocks Note Brake will still be in engaged mode Hub Retaining Nut Figure 14 Hub Assembly TEAR DOWN AND REASSEMBLY How to Use This Manual Each subassembly illustrated in this manual is illustrated with an exploded view showing the parts involved The item reference numbers in each illustration are for assembly instruc tions only See page 41 for part names and descriptions A complete exploded view and item list of the transaxle is provided at the end of the repair section General Instructions 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 us ing 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 Protect all exposed sealing surfaces and open cavities from damage and foreign material The external surfaces should be cleaned before beginning any repairs Do not use a pressure washer to clean the transaxle 20 Upon removal i
32. he first removing the spring 147 and Torx table on page 21 for the required torque head screw 46 The remaining members values of the assembly can be removed as a single item washer 146 unidirectional scissor arm kit 145 and the control arm 44 19 3 Remove the Allen head screw 142 washer 3 Refer to the RTN adjustments on page NOTE As a general rule use the low end of 45 neutral arm 141 and spacer 140 the torque specification on fasteners when reassembling the unit NOTE Only remove the seal 41 if damaged or worn The seal is not part of the control arm kit 211 and cannot be serviced separately Refer to Seal Kit in the Items List on page 41 Inspection 1 Inspect all parts for excessive wear or dam age Replace if necessary REFER ro RETURN TO NEUTRAL SETTING ON Pace 13 36 2 SN AME Figure 8 Return to Neutral Assembly 14 ZT 2800 CONTROL ARM ASSEMBLY Refer to Figure 9 Disassembly Assembly 1 Remove all items previously discussed in 1 Reassemble all parts in the reverse order their recommended order of disassembly 2 Remove the lock nut 47 the washer 45 2 When tightening the fasteners refer to the and the Torx head screw 46 table on page 20 for the required torque values 3 Remove the control arm 44 the washers 43 and the stud 42 NOTE As a general rule use the low end of the torque spec on fasteners when
33. he 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 ISS or the plug 5 Y for horizontal installation NI LAN WY Drain port 4 x A 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 10 ZT 2800 FLUID CHANGE PROCEDURE This transaxle is designed with an external filter for ease of maintenance To ensure constant fluid quality levels and longer life an initial oil and filter change at 75 100 hours then every 400 hours thereafter is recommended The following procedure can be performed with the transaxles installed in the vehicle and the vehicle on level ground Apply the bypass valve for each transaxle and lock the vehicle parking brake 1 Remove the three 1 4 filter guard screws and filter guard Clean any loose debris from around the perimeter of the filter See figures 4 and 5 2 Place an oil drain pan 12 or more diam eter and 8 qt capacity is optimal beneath the oil filter Remove the oil filter from the transaxle 3 Afterthe oil has drained wipe the filter base surface off and apply a film of new oil to the gasket of the new replacement filter Hydro Gear part number 52114 4 Install th
34. is reached on the Hydro Gear expansion tank refer to vehicle owner s manual for specific volumes 13 Re install the expansion tank cap by hand Be careful to not overtighten 14 Proceed to the purge procedure Screws gt Figure 6 Filter And Filter Guard 11 PURGING PROCEDURES Due to the effects air has on efficiency in hy drostatic drive applications it is critical that it is purged from the system Air creates inefficiency because its compres sion and expansion rate is higher than that of the oil approved for use in hydrostatic drive systems These purge procedures should be imple mented any time a hydrostatic system has been opened to facilitate maintenance or the oil has been changed The resulting symptoms in hydrostatic systems may be 1 Noisy operation 2 Lack of power or drive after short term op eration 3 High operation temperature and excessive expansion of oil Before starting make sure the transaxle is at the proper oil level If it is not fill to the specifi cations outlined in this manual 12 The following procedures are best performed with the vehicle drive wheels off the ground Then repeated under normal operating condi tions If this is not possible then the procedure should be performed in an open area free of any objects or bystanders 1 Disengage the brake if activated 2 With the bypass valve open and the engine running slowly move the directional cont
35. lug nuts Do not remove the axle hub nut 2 Remove the Original Equipment Manufac turer s OEM s control linkage at the control arm 3 4 WARNING Do not attempt any servicing or ad justments 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 Start the engine and increase the throttle to full engine speed Check for axle rotation If the axle does not rotate go to Step 5 If the axle rotates go to Step 6 Stop the vehicle s engine Reattach and adjust the vehicle s linkage according to the vehicle owner s manual Note the axle directional movement Stop the vehicle engine Loosen the RTN ad justment screw until the control arm can be rotated Rotate the control arm in the opposite direction of the axle rotation in 5 degree increments Tighten the RTN adjust ment screw Recheck according to steps 3 and 4 Refer to Figure 7 mMm ROTATION B Q ROTATION A RTN Adjusting Screw Speed and Direction Control Arm Figure 7 Return to Neutral Setting Z1 28009 RETURN TO NEUTRAL ASSEMBLY Refer to Figure 8 Disassembly Assembly 1 Remove all items previously discussed in 1 Reassemble all parts in the reverse order their recommended order of disassembly 2 Remove the control arm kit 211 by 2 When tightening the fasteners refer to t
36. nd of the torque specification on fasteners when reassembling the unit 203 Figure 21a Charge Pump 27 INPUT SHAFT Refer to Figure 22 Disassembly Assembly 1 Requires removal of all items beginning on 1 Reassemble all parts the reverse order page 22 of disassembly 2 Remove the retaining ring 57 3 Remove the lip seal 56 and discard 4 Remove the washer 55 and the pump shaft assembly 52 53 NOTE To assist in the removal of the pump shaft lightly tap using a neoprene head hammer the shaft from the charge pump side of housing Care should be taken not to damage the shaft or gerotor running surface 52 0 Remove the bearing from pump shaft only if worn or damaged ji 5 Remove the wire ring retainer 54 and the bearing 53 from the pump shaft 52 Inspection 1 Inspectthe bearing and input shaft for wear or damage Inspect the splines on the shaft for possible damage Replace if neces sary Figure 22 Input Shaft 28 ZT 2800 BYPASS ARM Refer to Figure 23 Disassembly 1 Requires removal of all items beginning on page 22 2 Remove the push on retaining ring 35 and discard Remove the bypass arm 34 3 Remove the retaining ring 33 4 Remove the bypass rod 32 and the clip retaining ring 31 as a single item NOTE It is not necessary to remove the clip retaining ring 31 from the bypass rod 32 unles
37. on Kit Seal Kit Center Section Kit Charge Relief Kit Charge Kit Fan and Pulley Puller Hub Kit Input Shaft Kit RTN Control Arm Kit Axle Shaft 41 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 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 reser voir 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 hydrostatic transaxle or 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 Entrained Air A mechanically generated mixture of air bubbles having
38. r 8 _ Date Julian Day of year Serial Number unique for that model for that day Type of Product and Build Information Figure 3 Configuration Label 6 ZT 2800 SAFETY This symbol points out important safety instructions which if not followed could en danger the personal safety and or property of yourself and others Read and follow all instruc tions in this manual before attempting mainte nance on your transaxle When you see this symbol HEED ITS WARNING WARNING POTENTIAL FOR SERIOUS INJURY Inattention to proper safety operation or maintenance procedures could result in personal injury or damage to the equip ment Before servicing or repairing the ZT 2800 transaxle fully read and under stand the safety precautions described in this section Personal Safety Certain safety precautions must be observed while servicing or repairing the ZT 2800 This section addresses some of these precautions but must not be considered an all inclusive 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 regula tions 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
39. rol in both forward and reverse directions 5 or 6 times 3 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 the engine 4 t may be necessary to repeat Steps 2 and 3 until all the air is completely purged from the system When the transaxle operates at normal noise levels and moves smoothly forward and reverse at normal speeds then the transaxle is considered purged ZT 2800 RETURN TO NEUTRAL SETTING WARNING POTENTIAL FOR SERIOUS INJURY Inattention to proper safety operation or maintenance procedures could result in personal injury or damage to the equip ment Before servicing or repairing the ZT 2800 transaxle fully read and under stand the safety precautions described in this section The return to neutral mechanism on the transaxle is designed to set the directional control into a neutral position when the operator releases the vehicle hand 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 Remove the wheel by removing the
40. s it is damaged or worn 5 Remove the lip seal 30 and discard Inspection 1 Inspectthe 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 Z1 28009 Assembly 1 Install a new lip seal 30 2 Install the clip retaining ring 31 and bypass rod 32 3 Install the retaining ring 33 4 Install the bypass arm 34 and new push on retaining ring 35 Figure 23 Bypass Arm 29 SWASHPLATE Refer to Figures 24 25 Disassembly 1 Requires removal of all items beginning on page 22 Remove the swashplate 40 and pump cylinder block assembly 69 as a single item Separate the pump cylinder block assembly 69 and the thrust bearing 65 from the swashplate 40 and set aside NOTE Removal will be aided by applying a small amount of pressure on the trun nion mounted swashplate towards the center section While CAREFULLY removing the swashplate and block as sembly keep the block face flush with the center section to minimize damage to the running surface Inspection 1 30 Inspect the swashplate 40 and thrust bearing assembly 65 for wear or damage Replace if necessary Inspect pump block per detail on page 32 Figure 24 Swash Plate Assembly de Reassemble all parts in the reverse order of disassembly Apply a light coating of oil to running sur faces on
41. tis recommended that all seals O rings and gaskets be replaced During installation lightly lubricate all seals O rings and gaskets with a clean petroleum jelly prior to assembly Also protect the inner diameter of seals during installation by covering the shaft with a cellophane or plastic wrap material Be sure all remnants of this covering are removed after servicing 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 in BLN 51427 CD IMPORTANT When internal repair is per formed on the ZT 2800 transaxle the oil filter must be replaced ZT 2800 TOOLS REQUIRED TOOLS Miscellaneous Sockets Hub Puller Flat Blade Screw Driver 2 Torque Wrench Air Impact Wrench Rubber or Neoprene Mallet Breaker Bar Side Cutters Snips Needle Nose Pliers Large External Snap Ring Pliers Small Internal Snap Ring Pliers 1 2 3 8 Adapter 3 8 Deep 1 1 8 Deep 1 4 Allen 3 4 Deep 9 16 Deep T 40 Torx Head 7 8 Deep REQUIRED TORQUE VALUES TORQUES Description 5 Plug 9 16 18 Metal 7 Screw Hex head 1 4 20 x 1 25 11 Plug 9 16 18 Metal 23 Filter 24 Check Plug or Shock Valve 25 Check Plug or Shock Valve 27 Screw Hex Head 3 8 16 x1 5 42 Stud Short 5 16 24 46 Torx Head Screw 5 16 24 x 1 00 47 Nut Hex Lock 5 16 24 UNF 99 Nut Hex Lock 3 4 16 105
42. to Figure 16 FAN AND PULLEY KIT 207 CONFIGURATION B 1 Remove the locknut 122 and detach the fan and pulley assembly from the input shaft 2 Separate the assembly by removing the screws 123 fan 120 and the pulley 121 Inspection 1 Check all components for excessive wear or damage Replace if necessary Assembly 1 Reassemble all parts in the reverse order of disassembly 2 When tightening the fasteners refer to the table on page 21 for the required torque values NOTE As a general rule use the low end of the torque specification on fasteners when reassembling the unit Figure 16 Fan Pulley Kit 207 Configuration Z1 28009 Refer to Figure 17 FAN AND PULLEY KIT 207 CONFIGURATION 1 Remove the locknut 122 and detach the fan and pulley assembly from the input shaft 2 Remove the hex head screws 123 to separate the fan 120 and pulley 121 as sembly Inspection 1 Check all components for excessive wear or damage Replace if necessary Assembly 1 Reassemble all parts in the reverse order of disassembly 2 When tightening the fasteners refer to the table on page 21 for the required torque values 122 Figure 17 Fan Pulley Kit 207 Configuration C 23 FAN AND PULLEY Continued Refer to Figure 18 Disassembly FAN AND PULLEY KIT 207 CONFIGURATION D 1 Remove the locknut 122 slotted washer 123 pulley 121 fan 1
43. to facilitate maintenance to bear ings bushings and seals externally WARNING POTENTIAL FOR SERIOUS INJURY Inattention to proper safety operation or maintenance procedures could re sult in personal injury or damage to the equipment Before servicing or repairing the transaxle fully read and understand the safety precautions described in the transaxle Service and Repair manual that pertains to the specific transaxle to be repaired Note Before using the Hub Removal Tool Hydro Gear P N 71241 apply a thin coat of anti seize to the bolt threads Thread the bolt in and out of the Hub Puller prior to using it for the first time 1 With the vehicle engine placed in the OFF position chock the front wheels engage the parking brake Raise the vehicle drive tires off the ground and remove the lug nuts from the vehicles drive wheel hub studs 2 Remove the hex retaining nut 3 4 16 from the center of the axle hub 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 4 Insert the hub removal tool over the flange wheel hub studs Install lug nuts and secure evenly Torque to 100 Ib in 11 3 Nm Z1 28009 Tighten the 1 1 8 socket head center bolt evenly and slowly Note This pressure will separate the hub from the tapered axle Remove the lug nuts and separate the hub removal tool from the flanged hub and dis card the old flan
44. ts Bypass assembly sticking Repair or replace linkage Page 9 Air trapped in hydraulic system Purge hydraulic system Page 12 Brake Partially Engaged Disengage Brake Replace Broken or Missing Brake Return Spring it Has Malte Power Engine speed low Adjust to correct setting Control linkage bent or out of adjustment Repair or replace linkage Page 9 Drive belt slipping or pulley damaged Repair or replace drive belt or pulley Page 9 Oil level low or contaminated oil Fill to proper level or change oil Page 11 Excessive loading Reduce vehicle loading Page 9 Bypass assembly sticking Repair or replace linkage Page 9 Air trapped in hydraulic system Purge hydraulic system Page 12 Brake Partially Engaged Disengage Brake Replace Broken or Missing Brake Return Spring Unit 18 Operating Her Debris buildup around transaxle Clean off debris Page 20 Cooling fan damaged Repair or replace cooling fan Pages 22 24 Oil level low or contaminated oil Fill to proper level or change oil Page 11 Excessive loading Reduce vehicle loading Page 9 Air trapped in hydraulic system Purge hydraulic system Page 12 Brake Partially Engaged Disengage Brake Replace Broken or Missing Brake Return Spring Transade Leaks Oil 0 00 Damaged seals housing or gaskets Replace damaged components Air trapped in hydraulic system Purge hydraulic system Page 12 ZT 2800 SERVICE AND MAINTENANCE External Maintenance Regular external maintenance of th
45. w end of below the torque specification on fasteners when reassembling the unit 2 When tightening the fasteners refer to the table on page 21 for the required torque values 2 Remove the retaining clip 103 3 Mark the position of the brake cam shaft 101 in relation to the brake handle 102 4 Remove the brake handle 102 5 Remove the hex head screws 105 and the cam stop retainer 104 Cam Stop Retainer 104 ORIENTATION Figure 12 Parking Brake Z1 28009 17 BRAKE ARM ASSEMBLY Code 3 Character 7 the model number code 3 Inspection Example ZX XXXX 3XXX XXXX 1 Inspect all parts for excessive wear or dam age Replace if necessary Refer to Figure 13 2 Inspect the splines on the brake arm and Disassembly brake shaft 1 Mark the position of the brake 102 in Assembly relation to the brake shaft 101 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 Figure 13 Parking Brake 18 ZT 2800 HUB REMOVAL Do not use this procedure to remove the drive wheel from the transaxle Remove the drive wheel by removing the lug nuts DESCRIPTION Follow the directions below for removal of 4 bolt flanged hubs from tapered axle shafts
46. x 40x 7 57 Ring Retaining 2 06 Internal 60 Bearing Thrust 64 Cylinder Block Motor 65 Bearing Thrust Ball 30 x 52 x 13 69 Cylinder Block Pump 70 Washer 63 x 1 0 x 05 71 Ring Retaining 62 External 72 Gear Pinion 16T 14T 13T 73 Shaft Motor 74 Washer 72 x 1 16 x 04 80 Washer 5 x 1 0 x 03 81 Gear Reduction 43T 45T 46T 82 Gear Reduction 11 T 83 Pin Jack Shaft 90 Ring Retaining 2 06 Internal 91 Gear Bull 54T 92 Spacer 750 x 1 000 x 257 93 Bearing Ball 75 x 40 x 12 94 Shaft Axle 95 Bearing Ball 1 0 x 52 x 15 Open 6205M an ZT 2800 96 97 99 100 101 102 103 105 106 109 111 120 121 121 122 123 123 123 124 130 131 132 133 134 135 136 137 140 141 142 145 146 147 200 201 202 203 207 209 210 211 212 Seal Lip 25 x 52 x 10 TC Gray Hub Nut Hex Lock 3 4 16 Pawl Brake Shaft Brake Handle Brake Clip Retaining Screw Hex Flange Head 1 4 20 x 75 Guard Filter Spacer Fitting STR 9 16 18 SAE 5 BARB Fan 7 0 10 Blade Pulley Disc Pulley Nut Hex Locking 1 2 20 Nylon Washer OD Slotted 53 x 1 63 x 0 HFHCS 1 4 20 x 75 HHCS 1 4 20 x 875 Pulley Tube Connecting Gerotor Assembly O ring 137 0 103 x 2 050 Cover Charge Pump Screw Hex Flange Head 1 4 20 x 75 Ball Spring Relief Pin Spring Spacer 320 x 1 005 x 179 Arm Neutral SHCS 5 16 24 x 1 Patch Assembly RTN Washer 343 x 1 500 x 062 Spring Extensi
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