Hydro-Gear ZT-2800 Installation and operating manual
ZT-2800®/ZT-3100®/ZT-3200™
Integrated Zero-Turn Transaxle
Service and Repair Manual
BLN-52441
January 2023
ZT-2800®/ZT-3100®/ZT-3200TM iZT-2800®/ZT-3100®i
Foreword ...................................................... 1
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............................ 2
Introduction................................................... 2
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........................................................... 7
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.................................... 21
............................................................ 22
Torques........................................................ 22
...................................... 23
........................................ 23-25
.................................................. 26
................ 27
.............................................. 29
................................................... 31
................................................. 32
.................................................. 33
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...................................... 35-36
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............................................ 39-40
.......... 41
.. 42
.................. 43
ZT-2800® .... 44-45
ZT-3100® .... 44-45
ZT-3200... 44-45
.................................. 46-47
Notes ........................................................... 48
Table Of Contents
ZT-2800®/ZT-3100®/ZT-3200TM 1ZT-2800®1
FOREWORD
®
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®
ZT-3100®
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Figure 1, Conguration Label
PRODUCT IDENTIFICATION
2 ZT-2800®/ZT-3100®/ZT-3200TM
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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.
Introduction
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®
ZT-2800®®
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-
Do not use a pressure washer to
clean the unit.
General Description
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DESCRIPTION AND OPERATION
ZT-2800®/ZT-3100®/ZT-3200TM 3ZT-2800®3
Figure 3, Hydraulic Schematic Without Charge Pump (ZT-2800)
HYDRAULIC SCHEMATIC
Figure 2, Hydraulic Schematic With Charge Pump
4 ZT-2800®/ZT-3100®/ZT-3200TM
EXTERNAL FEATURES ZT-2800®/ZT-3100®/ZT-3200TM
— Top View —
— Inboard View —
ZT-2800®/ZT-3100®/ZT-3200TM 5ZT-2800®5
EXTERNAL FEATURES ZT-2800®/ZT-3100®/ZT-3200TM
— Outboard View—Left (Standard Control) —
— Outboard View—Right (Return To Neutral Control) —
6 ZT-2800®/ZT-3100®/ZT-3200TM
TECHNICAL SPECIFICATIONS
SPECIFICATIONS ZT-2800®
ZH/ZJ ZK/ZL ZM
Reductions 20.69:1 24.74:1 27.23:1
0.61 in3
0.97 in3
SPECIFICATIONS ZT-3100®ZT-3200TM
ZJ ZL ZM ZM
Reductions 20.69:1 24.74:1 27.23:1 27.23:1
0.61 in3
0.97 in3
ZT-2800®/ZT-3100®/ZT-3200TM 7ZT-2800®7
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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
transaxle, fully read and understand
the safety precautions described in this
section.
Personal Safety
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tions.
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Tool Safety
Work Area Safety
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Servicing Safety
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-
be present.
“Discard used cleaning material in the ap-
propriate containers according to local,
state, and federal regulations.”
SAFETY
8 ZT-2800®/ZT-3100®/ZT-3200TM
TROUBLESHOOTING
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.
TROUBLESHOOTING CHECKLIST
Possible Cause Corrective Action
Unit Operates In One Direction Only
Vehicle Does Not Drive/Track Straight
Unit Is Noisy
Unit Has No/Low Power
Unit Is Operating Hot
Transaxle Leaks Oil
ZT-2800®/ZT-3100®/ZT-3200TM 9
Fluids
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“All uids should be handled and disposed of
according to local, state, and federal regula-
tions.”
Fluid Volume and Level
SERVICE AND MAINTENANCE
External Maintenance
2.
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Service and Maintenance Proce-
dures
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Fluid Description
ZT-2800/ZT-3100/ZT-3200
Correct oil volume is determined by characters 7 and 13 of
the model number. (Z*-****-X***-***X*)
Note: Theoilvolumegureshowndoesnotin-
cludewhatisintheexpansiontankhose
ortheexpansiontank.Thatwillhavetobe
determinedbythemachinemanufacturer/
enduserduetovaryinghosesizes/lengths
andexpansiontanksizes.
T
10 ZT-2800®/ZT-3100®/ZT-3200TM
FILTER AND FILTER GUARD
RefertoFigure4
Disassembly
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NOTE: Alwaysreplacethelterwhenperform-
ing any internal maintenance to the
transaxle.
Inspection
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Assembly
NOTE: Asageneralrule,usethelowendof
the torque specication on fasteners
whenreassemblingtheunit.
Figure 4, Filter and Guard
Whenrellingthetransaxlewithoil,
removetheportplug(5),ifinstalled,
andplug(11).Filluntiltheoilreachesthe
lowerlipofport(11)onsidecover.
23
106
105
111
5
11
Unitswillhaveinstalled,thetting
(111)ortheplug(5).
Breatherventonunitsequippedwith
internalexpansiontank.
ZT-2800®/ZT-3100®/ZT-3200TM 11
pro
Note: Before draining oil ensure the oil that will be
removed is less than 100°F before doing so. Units
equipped with an internal expansion tank will re-
tain oil that has expanded due to an increase in
Referencepage10forremoval.
Note: For units that do not have an external expan-
sion tank remove the ll port plug on the top of the
housing (gure 6).
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Note: For units that do not have an external expan-
sion tank replace the ll port plug on the top of the
housing (gure 6), torque to 120 in. lbs. and proceed
to the purge procedure on page 12.
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FLUID CHANGE PROCEDURE
Figure 5, Unit Without Internal Expansion Tank Figure 6, Unit With Internal Expansion Tank
CAUTION: Transaxles with internal expan-
sion tanks must be cool (less than 100°F)
before changing the oil. Failure to allow the
unit to cool prior to changing the oil could result
assembly.
Breatherventonunitsequippedwith
internalexpansiontank.
12 ZT-2800®/ZT-3100®/ZT-3200TM
PURGING PROCEDURES
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ZT-2800®/ZT-3100®/ZT-3200TM 13ZT-2800®13
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.
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
transaxle, fully read and understand
the safety precautions described in this
section.
RETURN TO NEUTRAL SETTING
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NOTE: It may be necessary to remove the
drive tire from the axle hub to access the
linkagecontrolandthetransaxlereturnarm.
Removethewheelbyremovingthelugnuts.
Donotremovetheaxle/hubnut.
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Figure 7, Return to Neutral Setting
w
ROTATION "B" ROTATION "A"
14 ZT-2800®/ZT-3100®/ZT-3200TM
RefertoFigure8
Disassembly
NOTE: Onlyremovetheseal(41)ifdamaged
or worn. The seal is not part of the
RTNcontrolarmkit(211),andcannot
beservicedseparately.Referto“Seal
Kit”intheItemsListonpager46.
Inspection
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Assembly
13.
NOTE: Asageneralrule,usethelowendof
the torque specication on fasteners
whenreassemblingtheunit.
RETURN TO NEUTRAL ASSEMBLY
Figure 8, Return to Neutral Assembly
211
46
146
145
14244
141
45
140 147
41
ZT-2800®/ZT-3100®/ZT-3200TM 15ZT-2800®15
CONTROL ARM ASSEMBLY
RefertoFigure9
Disassembly
NOTE: Onlyremovetheseal(41)ifdamaged
orworn.Thesealcannotbeserviced
separately. Refer to “Seal Kit” in the
ItemsListonpage46.
Inspection
-
Assembly
NOTE:
NOTE: Asageneralrule,usethelowendof
the torque spec on fasteners when
reassemblingtheunit.
Figure 9, Control Arm Assembly
47
41
45
44
43
42
46
16 ZT-2800®/ZT-3100®/ZT-3200TM
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tion.
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Figure 10, Brake Handle Orientation Figure 11, Brake Handle Removal
ZT-2800®/ZT-3100®PARKING BRAKE ADJUSTMENT (Code 1 or 2)
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.
Only
if Character #7 in the model number
code is 1 or 2.
Example: ZX-XXXX-1XXX-XXXX
or
ZT-2800®/ZT-3100®/ZT-3200TM 17ZT-2800®17
ZT-2800®/ZT-3100® PARKING BRAKE ASSEMBLY (Code 1 or 2)
RefertoFigure12
Disassembly
NOTE: The orientation of the cam stop and
brake-camtooneanotherisveryim-
portant. Indicate their relationship to
eachotheronthesidecovertoassist
in their correct assembly. See Insert
below.
Figure 12, Parking Brake
Inspection
-
Assembly
NOTE: Asageneralrule,usethelowendof
the torque specication on fasteners
whenreassemblingtheunit.
Only
if character #7 in the model number
code is 1 or 2.
Example: ZX-XXXX-1XXX-XXXX
or
105
102
103
ORIENTATION
18 ZT-2800®/ZT-3100®/ZT-3200TM
ZT-2800®/ZT-3100®/ZT-3200TM BRAKE ARM ASSEMBLY
(Code 3/5/6/7)
RefertoFigure13
Disassembly
NOTE: Theorientationofthebrakearmand
brakeshafttooneanotherisveryim-
portant.
Inspection
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Assembly
Figure 13, Parking Brake
Character #7 in the model number code is
3, 5, 6 or 7.
Example: ZX-XXXX-3XXX-XXXX
102
103
or
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