Hydro-Gear ZT-5400 Powertrain Service And Repair Manual Download

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BLN-0014

August 2010

ZT-5400 Powertrain™

Service and Repair Manual

www.mymowerparts.com

Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983

Summary of Contents for ZT-5400 Powertrain

Page 1: ...BLN 0014 August 2010 ZT 5400 Powertrain Service and Repair Manual www mymowerparts com Hydro Gear Parts or New Units Call 606 678 9623 or 606 561 4983 ...

Page 2: ...www mymowerparts com Hydro Gear Parts or New Units Call 606 678 9623 or 606 561 4983 ...

Page 3: ...Instructions 14 Tools 15 Torques 15 Transaxle Removal 16 Fan and Pulley 17 Axle Hub Assembly 17 Return to Neutral Assembly Option 18 Control Arm Assembly 19 Filter And Filter Cover 20 Brake Assembly 21 2 Speed Arm 22 Bypass Actuator 23 Side Housing 24 Axle Shaft And Planetary Gear Set 25 Charge Pump And Oil Tube 26 Input Shaft 27 Swashplate 28 Center Section 29 Brake Assembly And Motor Shaft 30 Mo...

Page 4: ...ipped 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 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 sh...

Page 5: ...ing procedures Should 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 5400 Powertrain is a self contained unit designed for the transfer and control of power It provides an infinitely variable speed range between...

Page 6: ... motor has a fixed displacement angle it is forced to turn with the flow of oil As the angle of the pump swashplate is increased the amount of oil being pumped will increase and cause a higher speed output of the motor Reversing the angle of the swashplate will reverse the direction of oil flow During the operation of the transaxle fluid is lost from the hydraulic loop through leak paths designed ...

Page 7: ...ANSION TANK PORT OIL COOLER PORT OPTIONAL BYPASS ACTUATOR TWO SPEED ARM OPTIONAL OIL FILL VENT PORT CHARGE PUMP Bottom View EXTERNAL FEATURES ZT 5400 Powertrain Inboard View www mymowerparts com Hydro Gear Parts or New Units Call 606 678 9623 or 606 561 4983 ...

Page 8: ...ARM EXPANSION TANK PORT FILL PORT OIL FILL VENT PORT INPUT SHAFT RTN EXTERNAL FEATURES ZT 5400 Powertrain Top View Outboard View Control Arm Return to Neutral www mymowerparts com Hydro Gear Parts or New Units Call 606 678 9623 or 606 561 4983 ...

Page 9: ... Input Speed Maximum Minimum 3600 rpm 1800 rpm Output Torque Peak Continuous 680 lb ft 921 N m 197 lb ft 267 N m 835 lb ft 1132 N m 234 lb ft 317 N m Weight on Tires per unit Maximum with 23 tires Maximum with 24 tires 800 lb 362 8 kg 668 lb 302 9 kg Axle Shaft End Options 4 Bolt Flange 5 Bolt Flange Parking Brake Type Internal Disc Weight of Unit 55 lb 24 9 kg Figure 2 Configuration Label Product...

Page 10: ...rmance of your job Never allow untrained or unauthorized person nel to service or repair the equipment 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 ...

Page 11: ...ing Page 9 Bypass assembly sticking Repair or replace linkage Page 9 Air trapped in hydraulic system Purge hydraulic system Page 11 Brake Partially Engage Disengage Brake Replace Broken or Missing Brake Return Spring Unit Is Operating Hot Debris buildup around transaxle Clean off debris Page 9 Cooling fan damaged Repair or replace cooling fan Pages 17 Oil level low or contaminated oil Fill to prop...

Page 12: ...it actuates and releases fully SERVICE AND MAINTENANCE PROCEDURES All the service and maintenance procedures presented on the following pages can be performed while the ZT 5400 Powertrain is mounted on the vehicle Any repair procedures as mentioned in the tear down and assembly section of this manual must be performed after the unit has been removed from the vehicle FLUIDs The fluids used in Hydro...

Page 13: ...l a new filter Hydro Gear part number 71943 Install a new O ring onto the filter cover and install the filter cover See Figure 3a See page 15 for torque specifications 4 Remove the top oil fill vent port plug see page 5 and fill the transaxle with new 20W50 motor oil through the expansion tank port fill port until oil reaches the oil fill vent port 5 Install the top oil fill vent port plug and con...

Page 14: ...ans mission is at the proper oil level If it is not fill to the specifications outlined on page 9 The following procedures should be performed with the vehicle drive wheels off the ground then repeated under normal operating condi tions 1 With the bypass valve open and the engine running slowly move the directional control in both forward and reverse directions 5 to 6 times as air is purged from t...

Page 15: ...ssary to remove the drive tire from the axle hub to access the linkage control and the transaxle return arm 2 Remove the Original Equipment Manufac turer s OEM s control linkage at the control arm 3 Start the engine and increase the throttle to full engine speed 4 Check for axle rotation If the axles do not rotate go to Step 5 If the axles rotate go to Step 6 5 Stop the vehicle s engine Reattach a...

Page 16: ...165 FORANY OTHER REASON DURING THE DISASSEMBLY OF THIS UNIT 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 2 Remove the Original Equipment Manufactur er s OEM s control linkage at the 2 speed control arm 168 Posi...

Page 17: ...s O rings gaskets with a clean petroleum jelly prior to assembly Also protect the inner diameter of seals by covering the shaft with a cellophane plastic wrap etc material Be sure all rem nants of this covering are removed after ser vicing Anytime the tapered axle hub is removed it should be replaced by a new axle hub insuring that the integrity of the taper lock is not lost Parts requiring replac...

Page 18: ...bs 2 25 3 38 Nm Center Section Magnet 52 Stud 50 120 in lbs 5 7 13 5 Nm RTN 56 TWHCS 230 310 in lbs 25 9 30 0 Nm RTN 57 Nut 85 120 in lbs 9 6 13 5 Nm RTN 61 SHCS 175 200 in lbs 19 7 22 5 Nm RTN 67 Screw 175 200 in lbs 19 7 22 5 Nm RTN 113 Castle Nut 275 350 ft lbs 372 9 474 5 Nm Hub 126 Nut 660 800 in lbs 74 5 90 3 Nm Brake Shaft 145 Screw 80 120 in lbs 9 0 13 5 Nm Gerotor Cover 152 Plug Oil Filte...

Page 19: ...d in the order recommended for a Figure 7 ZT 5400 Powertrain Transaxle TRANSAXLE REMOVAL complete tear down of the transaxle Do not disassemble the unit any far ther than necessary to accomplish the required repairs Reassembly is accomplished by per forming the Assembly portions of the procedures If the unit has been com pletely disassembled a summary of the assembly procedures in the order in whi...

Page 20: ... the castle nut 113 3 Remove the taper hub assembly 111 and discard NOTE A new hub will have to be ordered to replace the discarded hub 4 Remove the axle cover 115 5 Remove the axle shaft key 110 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 castle nut 113 refer to the ta...

Page 21: ...r 58 NOTE Only remove the seal 51 and the RTN control arm stroke limiter 65 if dam aged or worn Mark the orientation of the stroke limiter before removal Inspection 1 Inspect all parts for excessive wear or dam age 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 15 for the required torque values 3 I...

Page 22: ...top plate 65 if damaged or worn or if doing a complete disassembly Mark the orientation of the stop plate before removal Inspection 1 Inspect all parts for excessive wear or dam age 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 15 for the required torque values 3 Install new Torx head screw 56 and...

Page 23: ...nspection 1 Inspect all parts for wear or damage Re place as necessary 2 Check for old filter grommet stuck on the filter tube Remove if present Assembly 1 Install the new filter 150 2 Install the new O ring 151 onto the cover 152 3 Install the filter cover 152 Refer to torque chart on page 15 Figure 11 Filter and Filter Cover www mymowerparts com Hydro Gear Parts or New Units Call 606 678 9623 or...

Page 24: ... 4 Remove the brake handle 130 and the bushing 128 5 Remove the seal 127 and discard NOTE Only remove the seal 127 if damaged or worn or if doing a complete disas sembly Inspection 1 Inspect all parts for wear or damage Re place as necessary Assembly 1 Reassemble all parts in the reverse order of disassembly 2 Install new seal 127 from seal kit Figure 12 Brake Assembly www mymowerparts com Hydro G...

Page 25: ...he seal 164 if damaged or worn or if doing a complete disas sembly 2 SPEED ARM Optional Figure 13 2 Speed Arm Inspection 1 Inspect the 2 speed actuating handle 168 and the 2 speed lock down arm 165 for excessive wear or damage Replace if nec essary Assembly 1 Reassemble all parts in the reverse order of disassembly 2 Install the new seal 164 from seal kit 3 Install the 2 speed lock down arm 165 wa...

Page 26: ... doing a complete disas sembly Inspection 1 Inspect the actuator bypass rod 43 for wear or damage Replace if necessary NOTE Take care to insure that the actuator bypass rod is free of burrs that may cut the rubber lip seal 2 Inspect the housing bore Assembly 1 Reassemble all parts in the reverse order of disassembly 2 Install a new lip seal 41 3 Install two new O rings onto the actuator bypass rod...

Page 27: ...r damage Replace if necessary SIDE housing Assembly 1 Reassemble all parts in the reverse order of disassembly 2 Apply a bead of sealant around the perim eter of the main housing face See Sealant Application Diagram on page 34 3 Align the side housing 2 with the main housing 1 Use care not to smear the seal ant bead 4 Install the seventeen housing screws 6 Refer to the screw tightening pattern on ...

Page 28: ...her 104 4 Remove the axle shaft thrust ball 100 from the main house 1 5 Remove the axle retaining ring 101 axle shaft spacer 102 axle gear 94 ring gear 95 planet gears 96 sun gear 97 and the carrier 98 Inspection 1 Inspect all items of the planetary gear set for wear and or damage Assembly 1 Reassemble all parts in the reverse order of disassembly Figure 17 Planetary Gear Set Figure 16 Planetary G...

Page 29: ...rd the O ring 146 Inspection 1 Inspect items of the charge cover assem bly for wear and or damage Replace if necessary Assembly 1 Reassemble all parts in the reverse order of disassembly 2 When installing the charge pump cover 144 line up the mark on the cover with the mark on the housing refer to Disassembly step 3 3 When tightening the fasteners refer to the table on page 15 for the required tor...

Page 30: ...from pump shaft only if worn or damaged 5 Remove the wire ring retainer 72 and discard Remove the bearing 71 from the pump shaft 70 Inspection 1 Inspect the bearing and input shaft for wear or damage Inspect the splines on the shaft for possible damage Replace if neces sary Assembly 1 Reassemble all parts in the reverse order of disassembly 2 Install the input shaft assembly into the main housing ...

Page 31: ...hers 82 of the pump block assembly for scratches and or wear Replace the pump block assembly if necessary 3 Inspect for scratches on the machined sur faces of the swashplate 50 4 Inspect the pump cylinder block 88 Assembly 1 Reassemble all parts in the reverse order of disassembly 2 Apply a light coating of oil to all running surfaces 3 Reassemble the items of the pump block assembly Place the thr...

Page 32: ...d 22 4 Remove the center section assembly and motor block assembly Slide the motor block assembly off of the motor shaft Inspection 1 Inspect for surface wear damage scartches or scoring on the machined surfaces of the center section 20 Assembly 1 Reassemble all parts in the reverse order of disassembly 2 Apply a light coating of oil to all running surfaces 3 When tightening the fasteners refer to...

Page 33: ... Pull the motor shaft 90 retaining ring 192 and gear 93 out of the center section 20 3 Remove the brake rotor 123 and the washer 91 4 Remove the brake shaft nut 126 and washer 125 5 Remove the brake shaft 120 the splined cam 121 the puck cam 122 and brake puck 124 Inspection 1 Inspect for scratches and or damage to the brake rotor 123 2 Inspect the puck 124 for excessive wear 3 Inspect the gear 93...

Page 34: ...cam 161 and the 2 speed shaft 162 Inspection 1 Inspect the races of the thrust bearing 80 for wear or damage 2 Inspect the pistons 81 washers 82 and the motor cylinder block 84 of the motor block assembly for scratches and or wear Replace the motor block assembly if neces sary Assembly 1 Reassemble all parts in the reverse order of disassembly 2 Apply a light coating of oil to all running surfaces...

Page 35: ...ves 28 29 the springs 32 and the check spring retainers 30 5 Remove the charge pressure relief plug 36 the spring 35 and the ball 34 Inspection 1 Inspect the all items of the charge galley assembly for wear or damage Replace if necessary 2 Clean off the magnet 39 Assembly 1 Assemble items in reverse order of disas sembly 2 When tightening components refer to the table on page 15 for the required t...

Page 36: ...TEARDOWN 13 Install the bypass rod wave washer and retaining ring 14 Install the three planet gears 96 onto the carrier 98 and then onto the axle shaft 103 Install the sun gear 97 onto the axle shaft 103 Install the gear 94 thrust spacer 102 and retaining ring 101 onto the axle shaft and set assembly aside In stall the thrust ball 100 into the main hous ing Place the axle assembly into the main ho...

Page 37: ...ning ring 107 into the side cover 2 Place the axle shaft key 110 into the keyway on the axle Slide the hub 111 onto the axle and secure with the castle nut 113 20 Perform the purge procedures listed on page 11 NOTE Prior to applying the new sealant the old sealant must be removed from all surfaces A small consistent bead approx 1 16 1 8 inch of the sealant around the housing face will be sufficien...

Page 38: ...ence Starting with the number 1 screw location tighten sequentially through to 17 Torque each screw to 230 290 lb in 25 9 32 7 Nm NOTE As a general rule use the low end of the torque specification SIDE Housing SCREW TIGHTENING SEQUENCE www mymowerparts com Hydro Gear Parts or New Units Call 606 678 9623 or 606 561 4983 ...

Page 39: ...ternative proce dure outlined in this document All parts need to be clean and free of lubrication Procedure 1 Engage machine parking brake 2 Remove nut cover 3 Remove existing nut 4 Install new nut to 50 ft lbs 5 Mark a point on the new nut and hub per Figure 28 Point A 6 Measure 2 nut flats or 120º per Figure 28 and mark hub Point B 7 Turn nut clockwise until mark A lines up with mark B Figure 29...

Page 40: ...ZT 5400 Powertrain 37 www mymowerparts com Hydro Gear Parts or New Units Call 606 678 9623 or 606 561 4983 ...

Page 41: ...38 ZT 5400 Powertrain ZT 5400 Powertrain EXPLODED VIEW www mymowerparts com Hydro Gear Parts or New Units Call 606 678 9623 or 606 561 4983 ...

Page 42: ... 22T 98 Carrier 100 Ball Thrust 75 101 Ring Retaining 1 25 102 Spacer Thrust Axle 103 Shaft Axle 1 25 Taper 104 Washer 1 40 X 1 75 X 05 105 Bearing Ball 35 X 80 X 21 6307 106 Seal Lip 1 375 X 2 062 X 0 250 107 Ring Retaining Internal 110 Key Shaft Axle 111 Hub Taper 1 25 4 Bolt 112 Stud 1 2 20x1 5 Rib Neck 113 Castle Nut Hex 1 20 Slotted 114 Axle Cap 116 Pin Cotter 9 64 120 Shaft Brake 121 Cam Spl...

Page 43: ...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 End Cap See Center Section Entrained Air A mechanically generated mixture of air bubbles having a tendency to separate from the liquid phase Gerotor A formed rotor set operatin...

Page 44: ...e air a path of 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 repl...

Page 45: ...42 ZT 5400 Powertrain Notes www mymowerparts com Hydro Gear Parts or New Units Call 606 678 9623 or 606 561 4983 ...

Page 46: ...ZT 5400 Powertrain 43 Notes www mymowerparts com Hydro Gear Parts or New Units Call 606 678 9623 or 606 561 4983 ...

Page 47: ...www mymowerparts com Hydro Gear Parts or New Units Call 606 678 9623 or 606 561 4983 ...

Page 48: ... 2010 HYDRO GEAR Printed in U S A Rev P9 www mymowerparts com Hydro Gear Parts or New Units Call 606 678 9623 or 606 561 4983 ...

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