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Hydro-Gear ZT-3600 User Manual

Hydro-Gear ZT-3600
52 pages
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ZT-2800
®
/ZT-3100
®
/ZT-3200™/ZT-3400
®
Integrated Zero-Turn Transaxle
Service and Repair Manual
BLN-52441
January 2018

Questions and Answers:

Hydro-Gear ZT-3600 Specifications

General IconGeneral
SeriesZT-3600
ApplicationCommercial Zero-Turn Mowers
Input Speed (Rated)3600 RPM
Maximum Input Speed3600 RPM
TypeHydrostatic
Oil Capacity64 oz
Fluid Capacity64 oz
Oil Type20W-50 motor oil
Input Shaft Diameter1.125 inches

Summary

Foreword

Product Identification

Description and Operation

Introduction

Provides information on servicing and troubleshooting the transaxles, including descriptions, schematics, and specifications.

General Description

Details the self-contained units, speed ranges, pump/motor design, and cooling system for the transaxles.

Hydraulic Schematic

External Features

Technical Specifications

Safety

Personal Safety

Outlines precautions for personal safety while servicing, referencing other safety materials and best practices.

Tool Safety

Emphasizes using proper tools and inspecting them for damage before use to prevent injury.

Work Area Safety

Advises keeping the work area neat, well-lit, and free of hazards like debris and trip hazards.

Servicing Safety

Addresses disabling the vehicle, hydrostatic braking loss, flammable liquids, and proper disposal of materials.

Troubleshooting

Service and Maintenance

External Maintenance

Lists essential checks like load ratings, oil level, drive belt, control linkage, and bypass mechanism.

Service and Maintenance Procedures

States that some procedures can be done on-vehicle, while repairs require removal.

Fluids

Discusses the importance of using specified fluids and handling them according to regulations.

Fluid Volume and Level

Provides information on total system volume and the specific transaxle volume.

Filter and Filter Guard

Disassembly

Details removing screws, filter guard, filter, and drain plug for maintenance.

Inspection

Advises inspecting parts for wear or damage and replacing them if necessary.

Assembly

Outlines reassembling parts in reverse order and filling with oil.

Fluid Change Procedure

Purging Procedures

Return to Neutral Setting

Return to Neutral Assembly

Disassembly

Describes removing various parts of the RTN control arm kit.

Inspection

Advises inspecting all parts for excessive wear or damage and replacing if necessary.

Assembly

Outlines reassembling parts in reverse order and referring to adjustment procedures.

Control Arm Assembly

Disassembly

Details removing lock nut, washer, screw, control arm, washer, and stud.

Inspection

Advises inspecting all parts for excessive wear or damage and replacing if necessary.

Assembly

Outlines reassembling parts in reverse order, noting items to discard.

Parking Brake Adjustment (ZT-2800/ZT-3100)

Parking Brake Assembly (ZT-2800/ZT-3100)

Disassembly

Details marking and removing cam stop retainer, clip, brake (cam) shaft, and brake handle.

Inspection

Advises inspecting parts for wear or damage and inspecting splines on handle and shaft.

Assembly

Outlines reassembling parts in reverse order and referring to torque values.

Brake Arm Assembly (ZT-2800/ZT-3100/ZT-3200/ZT-3400)

Disassembly

Details marking and removing retaining clip and brake arm.

Inspection

Advises inspecting parts for wear or damage and inspecting splines on brake arm and shaft.

Assembly

Outlines reassembling parts in reverse order.

Parking Brake Assembly (ZT-2800/ZT-3100) - Code A

Disassembly

Details removing various springs, nuts, and brake components.

Assembly

Outlines reassembling parts in reverse order and checking torque values.

Brake Setting

Explains how to set the brake by adjusting the castle nut and checking the gap.

Hub Removal

Description

Explains the procedure for removing hubs from tapered axle shafts for maintenance.

Tear Down and Reassembly

How to Use This Manual

Explains how subassemblies are illustrated with exploded views and reference numbers for assembly.

General Instructions

Emphasizes cleanliness, protecting surfaces, and using appropriate cleaning methods.

Tools

Torques

Fan and Pulley Kit Maintenance

Configuration A

Details disassembly, inspection, and assembly for Fan and Pulley Kit Configuration A.

Fan and Pulley Kit - Configuration B

Fan and Pulley Kit - Configuration D

Side Cover

Disassembly

Details removing external items, filter, screws, side cover, bearing, and spacer.

Inspection

Advises inspecting bearing and bushing areas for wear or damage.

Assembly

Outlines applying sealant, installing pins, side housing, and screws.

Bull, Pinion and Reduction Gears

Disassembly

Details removing washers, reduction gears, pinion gear, bull gear, and spacer.

Inspection

Advises inspecting bull gear teeth, splines, and reduction gears for wear or damage.

Assembly

Outlines installing washers, pinion gear, bull gear, jack shaft pin, and reduction gears.

Charge Pump

Disassembly

Details marking, removing screws, cover, gerotor assembly, O-ring, and connecting tubes.

Inspection

Advises inspecting the gerotor assembly for wear or damage.

Assembly

Outlines reassembling parts in reverse order, replacing O-rings, and aligning the cover.

Charge Pump Orientation

Input Shaft

Disassembly

Details removing retaining ring, lip seal, washer, and pump shaft assembly.

Inspection

Advises inspecting bearing and input shaft for wear or damage, and splines for damage.

Assembly

Outlines reassembling all parts in the reverse order of disassembly.

Bypass Arm

Disassembly

Details removing retaining rings, bypass arm, bypass rod, and lip seal.

Inspection

Advises inspecting the bypass rod for wear or damage.

Assembly

Outlines installing a new lip seal, clip retaining ring, bypass rod, retaining ring, and bypass arm.

Swashplate

Disassembly

Details removing swashplate, pump cylinder block assembly, and thrust bearing.

Inspection

Advises inspecting swashplate and thrust bearing assembly for wear or damage.

Assembly

Outlines reassembling parts in reverse order, applying oil, and aligning components.

Center Section

Disassembly

Details removing mounting screws, center section, motor shaft, block assembly, and brake shaft.

Inspection

Advises inspecting thrust bearing races, motor shaft, and center section machined surfaces.

Assembly

Outlines reassembling parts, applying oil, and aligning components before installation.

Brake Assembly (Code 1 or 2)

Disassembly

Details removing center section, brake cam shaft, brake puck, and O-rings.

Inspection

Advises inspecting all components for unusual wear or damage.

Assembly

Outlines installing new O-rings and the brake puck onto the brake cam shaft.

Brake Assembly (Code 3)

Disassembly

Details removing center section, brake shaft, brake pawl, and O-rings.

Inspection

Advises inspecting all components for unusual wear or damage.

Assembly

Outlines installing the brake pawl on the brake shaft and new O-rings.

Center Section Kit

Disassembly

Details removing bypass plate, plug seals, check plugs, and charge relief kit.

Inspection

Advises inspecting components for wear or damage, paying attention to ports and passages.

Assembly

Outlines installing charge relief kit, check plugs, plug seals, and bypass plate.

Check Plugs & Seals

Cylinder Blocks

Axle Shaft (ZT-2800/ZT-3100)

Disassembly

Details removing retaining ring, lip seal, axle shaft, and bearing.

Inspection

Advises inspecting splines on axle shaft and bearing for wear or damage.

Assembly

Outlines assembling items in reverse order, noting protection for lip seal.

Axle Shaft (ZT-3200/ZT-3400)

Disassembly

Details removing axle tube, retaining ring, lip seal, spacer, axle shaft, and bearing.

Inspection

Advises inspecting splines on axle shaft and bearing for wear or damage.

Assembly

Outlines assembling items in reverse order, noting protection for lip seal.

Assembly After a Complete Tear Down

Side Cover - Screw Tightening Sequence

How to Use the Service Schematic

Notes

Glossary of Terms

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