Cub Cadet ZT-3400- Manuals

Page 2 - Table Of Contents

ZT-2800 ® /ZT-3100/ZT-3400™ i Foreword ..................................................... . 1Description and Operation ........................... . 2Introduction .................................................. . 2Hydraulic Schematic .................................... . 3External Features .....

Page 3 - fOrewOrd; This is not a certification, test or study guide for

ZT-2800 ® /ZT-3100/ZT-3400™ 1 ZT-2800 ® 1 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...

Page 4 - warning; actuating the bypass will result in the; introduction; do not use a pressure washer to; general description

2 ZT-2800 ® /ZT-3100™/ZT-3400™ drives’ cool, quiet operation. An external filter on the transaxle allows for easy oil maintenance. 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 p...

Page 5 - HYdraULiC sCHeMaTiC

ZT-2800 ® /ZT-3100/ZT-3400™ 3 ZT-2800 ® 3 figure 2, Hydraulic schematic without Charge pump (ZT-2800) HYdraULiC sCHeMaTiC figure 1, Hydraulic schematic with Charge pump Vent Vent Bypass Motor Shaft Motor Pump Filter Charge Pump Charge Relief System Check Valves Input Shaft Case Reservoir Motor Shaft...

Page 8 - prOdUCT idenTifiCaTiOn; label found on the transaxle.; TeCHniCaL speCifiCaTiOns; Assembled in USA

6 ZT-2800 ® /ZT-3100™/ZT-3400™ Figure 3, Configuration Label prOdUCT idenTifiCaTiOn The model and configuration of the ZT-2800, ZT-3100 and ZT-3400 can be determined from the label found on the transaxle. ZT-2800 ® /ZT-3100 ZT-3400 Overall Transaxle reduction 20.69:1 ZH/ZJ 24.74:1 ZK/ZL 27.23:1 ZM 2...

Page 9 - personal safety; The floor should be clean and dry, and all ex; servicing safety; Some cleaning solvents are flammable. Use; safeTY

ZT-2800 ® /ZT-3100/ZT-3400™ 7 ZT-2800 ® 7 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. Whe...

Page 10 - TrOUBLesHOOTing; do not attempt any servicing or ad-

8 ZT-2800 ® /ZT-3100™/ZT-3400™ TrOUBLesHOOTing In many cases, problems with a transaxle 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 ...

Page 11 - API classification of SL is recommended. A; fluid Volume and Level; Certain situations may require additional fluid; service and Maintenance proce-; The fluids used in Hydro-Gear products have; fluid description

ZT-2800 ® /ZT-3100/ZT-3400™ 9 ZT-2800 ® 9 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. fluid Volume...

Page 12 - fiLTer and fiLTer gUard; Refer to Figure 4; disassembly; Always replace the filter when perform; inspection; Procedures,” page 11, steps 3 and 4 for filter

10 ZT-2800 ® /ZT-3100™/ZT-3400™ fiLTer and fiLTer gUard Refer to Figure 4 disassembly 1. Remove the hex head screws (105), and filter guard (106). 2. Remove the filter (23) and discard. NOTE: Always replace the filter when perform - ing any internal maintenance to the transaxle. 3. Remove the metal ...

Page 13 - fLUid CHange prOCedUre

ZT-2800 ® /ZT-3100/ZT-3400™ 11 ZT-2800 ® 11 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 ca...

Page 14 - pUrging prOCedUres; Due to the effects air has on efficiency in hy

12 ZT-2800 ® /ZT-3100™/ZT-3400™ 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 i...

Page 15 - reTUrn TO neUTraL seTTing; Confirm the transaxle is in the operating

ZT-2800 ® /ZT-3100/ZT-3400™ 13 ZT-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 s...

Page 16 - Refer to Figure 8; first removing the spring (147) and Torx; reTUrn TO neUTraL asseMBLY

14 ZT-2800 ® /ZT-3100™/ZT-3400™ Refer to Figure 8 disassembly 1. Remove all items previously discussed in their recommended order. 2. Remove the RTN control arm kit (211) by first removing the spring (147) and Torx head screw (46). The remaining members of the assembly can be removed as a single ite...

Page 17 - COnTrOL arM asseMBLY; Refer to Figure 9

ZT-2800 ® /ZT-3100/ZT-3400™ 15 ZT-2800 ® 15 COnTrOL arM asseMBLY Refer to Figure 9 disassembly 1. Remove all items previously discussed in their recommended order. 2. Remove the lock nut (47), and the washer (45). Discard both items. 3. Remove the Torx head screw (46).4. Remove the control arm (44),...

Page 18 - pOTenTiaL fOr seriOUs injUrY; Character #7 in the model number code = 1

16 ZT-2800 ® /ZT-3100™/ZT-3400™ 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. Note...

Page 20 - Refer to Figure 13; The orientation of the brake arm and; Inspect all parts for excessive wear or dam-; assembly; Reassemble all parts in the reverse order; Character #7 in the model number code = 3

18 ZT-2800 ® /ZT-3100™/ZT-3400™ BraKe arM asseMBLY (Code 3) Refer to Figure 13 disassembly 1. Mark the position of the brake arm (102) in relation to the brake shaft (101). NOTE: The orientation of the brake arm and brake shaft to one another is very im - portant. 2. Remove the retaining clip (103)....

Page 21 - for removal of flanged hubs from tapered axle; pertains to the specific transaxle to be; HUB reMOVaL; Insert the hub removal tool over the flange

ZT-2800 ® /ZT-3100/ZT-3400™ 19 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 flanged hubs from tapered axle shafts to facilitate maintenance to bearings, bushings and se...

Page 22 - general instructions; do not use a pressure; from the appropriate kits identified in the Items

20 ZT-2800 ® /ZT-3100™/ZT-3400™ Tear dOwn and reasseMBLYHow 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 pages 42-45 for part n...

Page 23 - TOOLs; TOrQUes; r e Q U i r e d T O O L s; item

ZT-2800 ® /ZT-3100/ZT-3400™ 21 TOOLs As a general rule, use the low end of the torque spec on fasteners when reassembling the unit. TOrQUes r e Q U i r e d T O O L s 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...

Page 24 - fan and pULLeY; Do not remove the; nspection; Check all components for excessive wear; TransaXLe reMOVaL

22 ZT-2800 ® /ZT-3100™/ZT-3400™ fan and pULLeY N O T E : I t i s n e c e s s a r y t o r e m o v e t h e transaxle from the vehicle before performing the repair procedures presented in this section. To remove the wheel from the hub, do so by removing the lug nuts. Do not remove the axle/hub nut unle...

Page 25 - Refer to Figure 17; Refer to Figure 16; As a general rule, use the low end of

ZT-2800 ® /ZT-3100/ZT-3400™ 23 Refer to Figure 17 FAN AND PULLEY KIT (207) CONFIGURATION “C” 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. i nspection 1. Check all co...

Page 26 - Refer to Figure 18

24 ZT-2800 ® /ZT-3100™/ZT-3400™ fan and pULLeY (Continued) Refer to Figure 18 disassembly FAN AND PULLEY KIT (207) CONFIGURATION “D” (ZT-2800/ZT-3100) 1. Remove the locknut (122), slotted washer (123), pulley (121), fan (120) and pulley disc (121) the from the input shaft. i nspection 1. Check all c...

Page 27 - Refer to Figure 19; Before scraping the old seal; side COVer

ZT-2800 ® /ZT-3100/ZT-3400™ 25 Refer to Figure 19 disassembly 1. Remove all external items previously dis- cussed in their recommended order. 2. Remove filter (23) and discard. Drain oil from transaxle. Refer to page 11. 3. Remove the screws (7), separate side cover (2) from main housing (1), using ...

Page 28 - Refer to Figure 20; Remove external items beginning on page; Separate the reduction gears and inspect; BULL, piniOn and redUCTiOn gears; and secure their placement with retaining

26 ZT-2800 ® /ZT-3100™/ZT-3400™ Refer to Figure 20 disassembly 1. Remove external items beginning on page 22. 2. Remove washer (80) and reduction gear set (81-82) as an assembly and set aside. Remove second washer (80) and jack shaft pin (83). 3. Remove the washer (70), retaining ring (71), pinion g...

Page 29 - CHarge pUMp

ZT-2800 ® /ZT-3100/ZT-3400™ 27 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 (133), gerotor assembly (131), and the O-ring (13...

Page 30 - inpUT sHafT; Requires removal of all items beginning on; Inspect the bearing and input shaft for wear

28 ZT-2800 ® /ZT-3100™/ZT-3400™ inpUT sHafT Refer to Figure 22 disassembly 1. Requires removal of all items beginning on page 22. 2. Remove the retaining ring (57).3. Remove the lip seal (56) and discard.4. Remove the washer (55) and the pump shaft assembly (52–54). 5. (ZT-3400) Remove the flat wash...

Page 31 - Refer to Figure 23; Take care to insure that the bypass rod; BYpass arM

ZT-2800 ® /ZT-3100/ZT-3400™ 29 figure 23, 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 r...

Page 32 - swasHpLaTe

30 ZT-2800 ® /ZT-3100™/ZT-3400™ swasHpLaTe figure 24, swash plate Refer to Figures 24-25 disassembly 1. Requires removal of all items beginning on page 22. 2. Remove the swashplate (40) and pump cylinder block assembly (69) as a single item. 3. Separate the pump cylinder block assembly (69) and the ...

Page 33 - CenTer seCTiOn; Refer to Figure 26; A bypass puck is located beneath the

ZT-2800 ® /ZT-3100/ZT-3400™ 31 CenTer seCTiOn figure 26, Center section Refer to Figure 26 disassembly 1. Requires removal of all items beginning on page 22. 2. Remove the center section mounting screws (27). 3. Remove the center section, the motor shaft (73), the motor cylinder block assembly (64) ...

Page 34 - Remove the center section per detail on; Inspect all components for unusual wear or

32 ZT-2800 ® /ZT-3100™/ZT-3400™ BraKe asseMBLY (Code 1 or 2) (ZT-2800/ZT-3100) Refer to Figure 27 disassembly 1. Remove the center section per detail on page 31. NOTE: Take note of the orientation of the brake cam (101) and the brake puck (100). 2. Remove the brake (cam) shaft (101) and the brake pu...

Page 35 - Refer to figure 29 for orientation

ZT-2800 ® /ZT-3100/ZT-3400™ 33 BraKe asseMBLY (Code 3) Refer to Figure 28 disassembly 1. Remove the center section per detail on page 31. NOTE: Take note of the orientation of the brake pawl (100) and the brake shaft (101). 2. Remove the brake shaft (101) and the brake pawl (100). 3. Remove the O-ri...

Page 36 - CenTer seCTiOn KiT; — Charge Relief Kit —; small film of grease on the bypass plate, will

34 ZT-2800 ® /ZT-3100™/ZT-3400™ figure 30, Center section Kit (201) CenTer seCTiOn KiT Refer to Figure 30 disassembly 1. Remove the bypass plate (22) from the center section. 2. Remove the plug seals (26) and discard. Refer to figure 31, on page 35. IMPORTANT: Before removing the check plugs, it is ...

Page 37 - CYLinder BLOCKs; refer to figure 31. After successfully

ZT-2800 ® /ZT-3100/ZT-3400™ 35 figure 32, pump/Motor Cylinder Block assembly 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 separa...

Page 38 - Inspect the splines on the axle shaft for wear; Assemble items in reverse order of disas-

36 ZT-2800 ® /ZT-3100™/ZT-3400™ aXLe sHafT (ZT-2800/ZT-3100) Refer to Figure 33 disassembly 1. Remove all items beginning on page 22.2. Remove the retaining ring (90).3. Remove and discard the lip seal (96).4. Remove the axle shaft (94) in the direction of arrow. 5. Remove the bearing (95). NOTE: Re...

Page 40 - following summary identifies the assembly pro; asseMBLY afTer a COMpLeTe Tear dOwn; Prior to applying the new sealant, the

38 ZT-2800 ® /ZT-3100™/ZT-3400™ If the unit has been torn down completely, the following summary identifies the assembly pro - cedures necessary to completely assemble the unit. Each assembly procedure is located by a page reference.The part reference numbers provided in each assembly procedure are ...

Page 41 - Starting with the number “1” screw location,; side COVer – sCrew TigHTening seQUenCe

ZT-2800 ® /ZT-3100/ZT-3400™ 39 figure 36, screw tightening sequence diagram Starting with the number “1” screw location, tighten sequentially through to “16.”To r q u e e a c h s c r e w t o 1 0 5 - 1 5 5 l b - i n (11.87 - 17.52 Nm). NOTE: As a general rule, use the low end of the torque specificat...

Page 42 - HOw TO Use THe serViCe sCHeMaTiC; Since character number 2 is “H”, the part number for item 81 is 52148.

40 ZT-2800 ® /ZT-3100™/ZT-3400™ HOw TO Use THe serViCe sCHeMaTiC (Online or schematic Cd) Locate the transaxle model number located on the transaxle. Refer to page 6. 1. Become familiar with the model number code by associating model number code characters 2. to component parts/unit attributes. See ...

Page 43 - nOTes

Page 44 - TransaXLe eXpLOded View

42 ZT-2800 ® /ZT-3100™/ZT-3400™ ZT-2800 ® /ZT-3100™ TransaXLe eXpLOded View iT eM s n OT sHO wn 13 Sealant 14 Oil, 20W50, 70.3 oz 200 Seal Kit 209 Hub Puller - S ea l K it co nt ai ns it em # ’s : 1 0, 2 6, 3 0, 3 1, 33 , 3 5, 4 1, 4 6, 5 6, 5 7, 7 1, 9 0, 9 6, 1 03 , 1 30 , 132, 156, 157, and 166

Page 45 - TransaXLe parTs LisT

ZT-2800 ® /ZT-3100/ZT-3400™ 43 ZT-2800 ® /ZT-3100™ TransaXLe parTs LisT 1 Housing, Main 2 Cover, Side 5 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...

Page 46 - ZT-3400 TransaXLe eXpLOded View

44 ZT-2800 ® /ZT-3100™/ZT-3400™ ZT-3400 TransaXLe eXpLOded View iT eM s n OT sHO wn 13 Sealant 14 Oil, 20W50, 70.3 oz 200 Seal Kit 209 Hub Puller - Seal Kit contains item #’ s: 6, 10, 26, 30, 31, 33, 35, 41, 46, 54, 56, 57, 71, 90, 96, 103, 130, 132, and 157

Page 47 - ZT-3400 TransaXLe parTs LisT

ZT-2800 ® /ZT-3100/ZT-3400™ 45 ZT-3400 TransaXLe parTs LisT 1 Housing, Main 2 Cover, Side 5 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 Pl...

Page 48 - gLOssarY Of TerMs

46 ZT-2800 ® /ZT-3100™/ZT-3400™ 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 ...