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EZT® Integrated Zero-Turn Transaxle Service and Repair Manual (ZC & ZD Models)

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EZT® Integrated Zero-Turn Transaxle Service and Repair Manual (ZC & ZD Models) EZT® Integrated Zero-Turn Transaxle Service and Repair Manual (ZC & ZD Models) BLN-52622 December 2008 TABLE OF CONTENTS Section Page Foreword .............................................................................................................................. 1 Description and Operation ................................................................................................. 2 Introduction .................................................................................................................................................. 2 General Description ..................................................................................................................................... 2 Hydraulic Schematic .................................................................................................................................... 3 External Features -EZT® ......................................................................................................................... 4 Technical Specifi cations ............................................................................................................................... 5 Product Identifi cation ................................................................................................................................... 5 Safety .................................................................................................................................... 6 Personal Safety ............................................................................................................................................ 6 Tool Safety ................................................................................................................................................... 6 Work Area Safety ......................................................................................................................................... 6 Servicing Safety ........................................................................................................................................... 6 Troubleshooting .................................................................................................................. 7 Service and Maintenance.................................................................................................... 8 External Maintenance .................................................................................................................................. 8 Service and Maintenance Procedures ......................................................................................................... 8 Fluids ........................................................................................................................................................... 8 Fluid Volume and Level ................................................................................................................................ 8 Fluid Change Procedure .............................................................................................................................. 9 Purging Procedures ................................................................................................................................... 10 Return to Neutral Setting ............................................................................................................................11 Repair ................................................................................................................................. 12 How To Use This Section ........................................................................................................................... 12 General Instructions ................................................................................................................................... 12 Transaxle Removal .................................................................................................................................... 12 Limited Disassembly .................................................................................................................................. 12 Tools and Torques ...................................................................................................................................... 13 Control Arm and Bypass Arm ..................................................................................................................... 14 Seal Kit Replacement ................................................................................................................................ 15 Cog Brake Assembly .................................................................................................................................. 16 Disc Brake Assembly ................................................................................................................................. 17 Side Cover ................................................................................................................................................ 18 Axle Shaft, Reduction Gears and Expansion Plate ....................................................................................19 Motor Shaft ................................................................................................................................................ 20 Input Shaft and Bypass Rod ...................................................................................................................... 21 Hydraulic Components .......................................................................................................................... 22-26 Transaxle Installation ................................................................................................................................. 26 Assembly After a Complete Teardown ....................................................................................................... 27 Sealant Application ........................................................................................................... 28 Parts List ...................................................................................................................... 30, 31 Glossary of Terms ....................................................................................................... 32, 33 FOREWORD Headquartered in Sullivan, Illinois, Hydro-Gear® Repair procedures require that the transaxle is a world leader in the design, manufacture, unit be removed from the vehicle. and service of quality hydrostatic transaxles for the lawn and garden industry. The mission of This is not a certifi cation, test or study guide for our company is to be recognized by our custom- a certifi cation test. If a technician is interested ers and the industry as a world-class supplier in certifi cation, they should contact an agent and the quality leader in everything we do. representing OPEESA (Outdoor Power Equip- ment and Engine Service Association) at (860) This Service and Repair Manual is designed 767-1770 or their Hydro-Gear Central Service to provide information useful in servicing and Distributor. Many distributors will be hosting troubleshooting the Hydro-Gear EZT® Inte- certifi cation testing. These study guides will grated Zero-Turn Transaxle. cover most of the products and manufacturers in our industry. Also included is a glossary of terms that are frequently used throughout the industry and in For more information about Hydro-Gear or our Hydro-Gear service publications. Understand- products, please contact your Central Service ing terminology is very important! Distributor, or call our Customer Service Depart- ment at (217) 728-2581. 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. EZT ® 1 SECTION 1. DESCRIPTION AND OPERATION INTRODUCTION of the swashplate reverses the fl ow of oil from the pump and thus reverses the direction of the The purpose of this manual is to provide infor- motor output rotation. The pump and motor are mation useful in servicing the Hydro-Gear® Inte- of the axial piston design and utilize spherical grated Zero-Turn Transaxle (EZT®). This man- nosed pistons which are held against a thrust ual includes the EZT’s general descriptions, race by internal compression springs. hydraulic schematics, technical specifi cations, servicing and troubleshooting procedures. The EZT has a self contained fl uid supply and an internal fi lter. The fl uid is forced through The transaxle normally will not require servic- the fi lter by a positive “head” on the fl uid in the ing during the life of the vehicle in which it is housing/expansion tank with an assist by the installed. Should other servicing be required, negative pressure created in the pump pistons the exterior of the transaxle will need to be as they operate. thoroughly cleaned before beginning most procedures. Do not wash the transaxle while The check valves in the center section are used it is hot. Do not use a pressure washer to to control the make-up fl ow of the fl uid to the clean the unit. low pressure side of the loop. GENERAL DESCRIPTION A cam style, block lifting bypass is utilized in The EZT is a self contained unit designed for the EZT to permit moving the vehicle for a short the transfer and control of power. It provides an distance at a maximum of 2 m.p.h.
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