Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
210-3010L
Introduction/General Description
Introduction
The purpose of this manual is to provide information useful
in servicing the 210-3010L Hydrostatic Transaxle. This
manual includes unit and component description, troubleshooting, maintenance, and repair procedures.
A transaxle normally will not require servicing, other than
recommended fluid and filter changes, if any, and an
occasional brake adjustment during the life of the vehicle in
which it is installed. Should other servicing be required, the
unit must be removed from its installed location and thoroughly cleaned before beginning most procedures.
General Description
The 210-3010L Hydrostatic Transaxle is a self contained unit
designed for the transfer and control of power. It provides an
infinitely variable speed range between zero and maximum
in both forward and reverse modes of operation.
The BDU-10L transmission is a “U” style transmission with
a variable displacement pump and a fixed displacement
motor. The variable displacement pump features a cradle
swashplate with a direct-proportional displacement control.
Reversing the direction of tilt of the swashplate reverses the
flow of oil from the pump and thus reverses the direction of
the motor output rotation. The fixed displacement motor
uses a fixed swashplate. The pump and motor are of the axial
piston design and utilize spherical nosed pistons which are
held against a thrust race by internal compression springs.
The 210-3010L Hydrostatic Transaxle is a package consisting of two primary components, the 210-3000 axle assembly
and the BDU-10L Hydrostatic Transmission.
BDU-10L Transmission
210-3000 Axle Assembly
Page 4
210-3010L
www.mymowerparts.com
Page 5
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
General Description
The fluid supply for the BDU-10L transmission is shared by
the axle. The oil passes from the axle housing through a filter
prior to entering the transmission and feeding the fixed
displacement gerotor charge pump. Excess fluid in the
charge circuit is discharged over the charge relief valve back
to charge pump inlet. Flow across a small fixed orifice
connecting the charge circuit to the transmission housing
supplements the cooling flow.
Charge check valves in the center section are used to control
the makeup flow of fluid to the low pressure side of the loop.
A spool type bypass valve is utilized in the BDU-10L
transmission to permit moving the vehicle for short distances at low speeds (2mph) (3.2km/hr) without starting the
engine.
The 210-3000 axle assembly is a spur gear reduction
transfer case with an integrated “heavy duty” spur gear
differential.
The 210-3000 axle assembly utilizes an inline floating disc
brake controlled by a “cam” style actuating arm.
210-3010L
Fluids/Greases
The fluids used in HYDRO-GEAR products have been
carefully selected, and only equivalent, or better products
should be substituted.
Typically, an engine oil with a minimum rating of 55 SUS at
210°F (98.9°C) and an API classification of SJ/CD is
recommended. A 10W-40 engine oil has been selected for
use by the factory and is recommended for normal operating
temperatures. Another alternative that will provide excellent
all climate performance and extended time between oil
changes is a 15W-50 synthetic engine oil.
SAE VISCOCITY GRADES
20W-50
10W-40
15W-50 Synthetic
-
35
o
o
o
-5
AMBIENT AIR TEMPERATURE
15
60
o
o
F
100
o
The grease used in the manufacture of HYDRO-GEAR
products is a Rykon Premium Grease and should be substituted for with equivalent products only if it is not readily
available in your area. NOTE:This grease is not compatible
with all grease types.
Hydrostatic Flow Illustration
210-3010L
www.mymowerparts.com
Page 5
Page 6
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
210-3010L
Safety Precautions
Certain procedures may require the vehicle to be disabled
(wheels raised off the ground, engine disconnected, etc.) in
order to prevent possible injury to the technician and bystanders.
Some cleaning solvents are flammable. To avoid possible
fire do not use cleaning solvents in an area where a source
of ignition may be present.
The loss of hydrostatic driveline power may result in the loss
of hydrostatic braking capacity. Proper brake maintenance
becomes very important should this condition develop.
Maintenance
Check the transaxle cooling fan for broken or distorted
blades, and check to see that the fan is securely fastened.
Replace the fan if damaged.
Keep the transaxle clean. Grass clippings and dirt will effect
the cooling efficiency of the fins on the transaxle housings.
Avoid high pressure washing, compressed air is the preferred method of removing loose debris.
Maintenance
210-3010L Hydrostatic Transaxle
Inspect the brake for proper operation. If the brake fails to
stop the vehicle or hold on a 30% slope, adjustments are
necessary. You should make sure it fully disengages when
the pedal is released.
Check to make sure the bypasss valve and linkage is
operational. The bypass valve should be fully released
before operating the vehicle. It should extend approximately
0.22" (5.58 mm) from the hex nut.
Inspect the transaxle for leaks at the lip seals, damage to
fittings, hoses, the filter, or to the housings. Check the oil
level and add oil as necessary to bring it up to the proper
level.
Page 6
210-3010L
www.mymowerparts.com
Page 7
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
Maintenance
Oil & Filter Change
Oil and filter changes should occur approximately every 200
hours of operation or once each year.
More frequent oil and filter changes are recommended if
operating conditions are severe or adverse, such as pulling
a plow or a tiller for extended periods, or operating in very
dusty conditions.
Refer to the following illustrations for the proper fill port and
oil level port locations on your transaxle. These locations will
be different on various models and it may be necessary to
refer to the vehicle owners manual.
Configuration A. Remove the filter and allow the oil to drain
through the filter mounting base. After the oil stops flowing
you may install the new filter and tighten 3/4 of one turn after
the filter seal touches the filter mounting base.
Configuration B. Drain the oil at bottom most fitting. Refer
to vehicle owners manual for correct procedures.
210-3010L
Configuration A
Refill the transaxle case to the correct level with the
recommended oil type listed in the Fluids section (refer to
illustrations for correct oil fill and oil level ports). The oil level
should be rechecked after running the vehicle for a short time
(1 minute will be adequate).
Configuration B
210-3010L
Page 7
www.mymowerparts.com
Page 8
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
210-3010L
Parking Brake
The brake was factory set for a specific running clearance
between the disc and pucks of 0.020" (.508 mm).
Place a feeler gage between the disc and one puck, if the
clearance is not set properly remove the cotter pin retaining
the castle nut and set the correct clearance by adjusting the
castle nut accordingly. Reinstall the cotter pin.
Maintenance
Brake Components
Brake Adjustments
If the correct adjustment was not achieved you will need to
replace the brake pucks. Start by removing the cotter pin,
castle nut, washer and brake actuating arm. Remove the
brake yoke assembly and pull the disc from the shaft.
Clean the brake area and all components thoroughly with a
degreasing solvent before reassembly.
During reassembly apply a dry graphite lubricant to the brake
shaft, brake actuating pins and cam area of the brake
actuating arm. Take precaution to not allow any lubricant
onto the brake disc or pucks during reassembly.
Reassemble the brake with new pucks and torque the bolt
and nut to 7-10 ft.lbs. (9.5-13.5 Nm).
Set the correct clearance (0.020") (.508 mm) and lock the
castle nut with the cotter pin.
Page 8
210-3010L
www.mymowerparts.com
Page 9
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
210-3010LTroubleshooting Diagram
OPERATES IN ONE DIRECTION ONLY
OPERATING HOT/LOSING POWER
210-3010L
NOISY UNDER LOAD
Page 9
www.mymowerparts.com
Page 10
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
210-3010L
Troubleshooting Chart
WARNING!!!
THE VEHICLE SHOULD BE ON LEVEL GROUND AND
THE ENGINE DISABLED BEFORE PERFORMING ANY ADJUSTMENTS
SYMPTOM - OPERATES IN ONE DIRECTION ONLY
POSSIBLE CAUSECORRECTIVE ACTION
-Inspect control linkage-Repair or replace
-Inspect drive belt & pulleys-Repair or replace
-Inspect check valves-Repair or replace
SYMPTOM - NOISY
POSSIBLE CAUSECORRECTIVE ACTION
-Check oil level & condition-Fill to proper level or change oil
-Check for excessive loading-Reduce vehicle loading
-Check brake setting-Adjust brake to proper setting
-Check for loose parts-Repair or replace loose parts
-Check bypass valve operation-Repair or replace valve or linkage
-Check inlet flow conditions-Repair or remove obstruction or leaks
-Inspect check valves-Repair or replace
SYMPTOM - LOW POWER
POSSIBLE CAUSECORRECTIVE ACTION
-Check engine RPM-Adjust to correct setting
-Check drive belt & pulleys-Repair or replace
-Check oil level & condition-Fill to proper level or change oil
-Check for excessive loading-Reduce vehicle loading
-Check brake setting-Adjust brake to proper setting
-Check for loose parts-Repair or replace loose parts
-Check bypass valve operation-Repair or replace valve or linkage
-Check inlet flow conditions-Repair or remove obstruction or leaks
-Check operating temperature-Repair or replace unit
-Inspect check valves-Repair or replace
SYMPTOM - OPERATING HOT
POSSIBLE CAUSECORRECTIVE ACTION
-Check bypass valve operation-Repair or replace
-Check for debris buildup-Clean off debris
-Check oil level & condition-Fill to proper level or change oil
-Check for excessive loading-Reduce vehicle loading
-Check brake setting-Adjust brake to proper setting
-Check cooling fan for damage-Repair or replace
-Inspect check valves-Repair or replace
Page 10
210-3010L
www.mymowerparts.com
Page 11
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
Minor Repairs
Minor Repairs
General Information
Minor Repairs may be performed, following the procedures
in this section, without voiding the unit warranty.
Cleanliness is a primary means of assuring satisfactory life
on either new or repaired units. Cleaning parts by using
solvent wash and air drying is usually adequate. As with any
precision equipment, all parts must be kept free of foreign
materials and chemicals.
Protect all exposed sealing surfaces and open cavities from
damage and foreign material. The outer surfaces must be
cleaned before beginning any repairs.
It is recommended that all O-rings and seals be replaced.
Lightly lubricate all O-rings and seals with a clean petroleum
jelly prior to assembly.
Each of the following repairs except brake adjustments will
require the oil levels to be checked prior to operating the
vehicle as some oil will be lost.
210-3010L
Shaft Seals
Lip type seals are used on the pump input shaft, pump
through shaft (not all models use the through shaft), motor
output shaft and displacement control shaft of the BDU-10L,
as well as on the brake shaft and axle shafts (in the main
housing halves only) of the 210-3000. These seals can be
replaced without major disassembly of the unit. However,
replacement of the seals generally requires removal of the
transaxle from the machine.
To replace the pump input shaft seal, first remove the
retaining ring from the housing.
Carefully pull the seal out of the housing bore. A “hook” type
tool may be used to grasp the seal and pull it out, or a slide
hammer type puller may be used to remove the seal. Care
must be taken so as not to damage the housing bore, shaft
sealing surface, or bearing. Once removed, the seal is not
reusable.
Inspect the sealing area on the shaft for rust, wear, or
contamination. Polish the sealing area on the shaft if
necessary.
Plug/Fitting Torques
If any plugs were removed during servicing, they should be
torqued as indicated in the accompanying table:
SNOITACIFICEPSEUQROT
NOITAREPOEUQROTNOITPIRCSEDTRAP
gulPssapyB
)s(gulPkcehC
gnittiF/gulPleetS
gnittiF/gulPleetS
gnittiF/gulPleetS
gnittiF/gu
lPleetS
081
sblni021-48
)mN5.31-5.9(
sblni042-081
)mN72-02(
sblni021-69
)mN5.31-8.01(
sblni042-
)mN72-02(
sblni042-081
)mN72-02(
sblni042-081
)mN72-02(
rtSEAS81-61/9
daerhTthgiartSEAS02-61/7
daerhTthgia
daerhTthgiartSEAS61/7
daerhTthgiartSEAS61/9
daerhTthgiartSEAS4/3
daerhTthgiartSEAS8/7
Retaining Ring Removal
210-3010L
Lip Seal Removal
Page 11
www.mymowerparts.com
Page 12
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
210-3010L
Shaft Seals
Lubricate the new seal with petroleum jelly.
Wrap the spline or key end of the shaft with with a thin plastic
or cellophane to prevent damage to the seal lip during
installation.
Slide the seal over the shaft and press it into the housing
bore. Be careful not to damage the seal.
Install the retaining ring in the housing.
The pump through shaft, motor output shaft, displacement
control shaft, and brake shaft seals may be replaced by
following a similar procedure as outlined for the pump input
shaft seal. These seals are not held in position by a retaining
ring. The replacement of axle shaft seals requires the
removal of the axle mounting horn while the replacement of
the seals on pump through shaft and the motor output shaft
requires removal of the BDU-10L from the 210-3000 axle
assembly.
Minor Repairs
Charge Check Valves
Remove the check valve plug with a 1/4" internal hex
wrench.
Remove the check valve spring and check ball (or poppet)
from the center section.
CAUTION: Do not allow the check ball to fall into the
closed loop passages in the center section. Removal
may be difficult but can be accomplished with a magnet,
or by removing the plug from the end of the center
section. Do not allow contaminants to be introduced to
the system.
Inspect the check balls (or poppets) and mating seats in the
center section for damage or foreign material.
Lip Seal Installation
Retaining Ring Installation
Page 12
Check Valve Removal/Installation
Check Valve Options
210-3010L
www.mymowerparts.com
Page 13
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
210-3010LMinor Repairs
Position the transmission so that the check valve port will be
in the upright position (as shown) and install the check ball
(or poppet), spring and plug (with o-ring) into the center
section. Make sure the plug stem is properly positioned into
the poppet or damage and failure will occur. Be certain the
check ball does not fall into the closed loop passage.
Torque the plug to 15-20 ft.lbs. (20-27 Nm).
Turn the unit over and repeat the procedure for the other side.
Bypass Valve
Removal of the bypass valve will require the BDU-10L to be
removed from the 210-3000 axle assembly.
Remove the bypass valve plug with a 9/16" hex wrench.
Remove the bypass valve plug, spool and spring from the
transmission center section.
Inspect the valve spool and mating bore in the center section
for damage or foreign material. The spool must move freely.
It is recommended that the o-rings be replaced.
Charge Pump Disassembly
Repair to the charge pump will require the BDU-10L transmission to be removed from the 210-3000 axle assembly.
The correct charge pump orientation is determined by the
rotation of the pump shaft (CW or CCW).
Before removing the charge pump, make note of, or mark its
position to simplify the reassembly process.
Using a 5mm internal hex wrench, remove the two screws
holding the charge pump cover on.
Remove the charge pump cover and o-ring. Avoid turning or
twisting the charge cover during removal, or damage to the
charge relief spring may occur.
Remove the charge pump gerotor assembly.
Standard Charge Pump Cover Orientation
Retain the valve spring to the valve spool with petroleum
jelly. Install the valve spool, spring and plug (with o-ring) into
the center section. Torque the plug to 7-10 ft.lbs.
(9.5-13.5 Nm).
Depress the bypass valve several times to insure that it
operates smoothly and fully closes. The bypass “button”
should extend from the hex plug approximately 0.22"
(5.58 mm) when fully released (closed).
(CW)(CCW)
Bypass Valve
210-3010L
Page 13
www.mymowerparts.com
Page 14
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
210-3010L
Charge Pump Disassembly
For models with a through shaft: Remove the charge
pump drive pin, spacer plate and o-ring. Make note of, and/
or mark the top and/or bottom of the spacer plate.
Remove the charge relief valve spring and ball.
Inspect the gerotor assembly, charge pump cover, and
center section (or spacer plate) for abnormal wear, damage
or foreign material. Inspect the charge relief valve ball and
spring. Inspect the charge relief valve seat in the center
section for damage or foreign material.
Charge Pump Assembly
Prior to reassembly of the charge pump, apply a small
quantity of petroleum jelly to the I.D., O.D., and faces of the
gerotor assembly.
Minor Repairs
NOTE: Improper assembly of the charge relief valve
spring and ball, or the incorrect orientation of the spacer
plate and cover will cause a priming failure. If assembled
properly, the charge pressure should be maintained at 2570 PSI (1.7-4.8 bar) at 3000 RPM pump speed.
For Standard Charge Pump: Install the charge relief
valve spring and ball. Install the gerotor assembly. Install
a new o-ring and the charge pump cover. NOTE:The
charge relief spring must enter the recessed hole in the
charge pump cover. Torque the bolts evenly to 7-10 ft.lbs.
(9.5-13.5 Nm).
For Through Shaft Charge Pumps: Install the charge
relief valve spring and ball. Install a new o-ring and the
spacer plate onto the aligning pins. NOTE: The charge
relief spring must enter the recessed hole in the spacer
plate. Install the charge pump drive pin. Install the gerotor
assembly. Install a new o-ring and charge pump cover.
Torque the bolts evenly to 7-10 ft.lbs. (9.5-13.5 Nm).
BDU-10L With Standard Charge PumpStandard Charge Pump Components
Through Shaft Charge Pump ComponentsBDU-10L With Through Shaft Charge Pump
Page 14
www.mymowerparts.com
210-3010L
Page 15
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
Minor Repairs
Axle Mounting Horn Assembly
Replacement of the axle mounting horn assembly can be
accomplished with a minimum loss of oil if the 210-3010L
transaxle is removed from the vehicle and situated with the
axle assembly to be replaced in the upright position.
210-3010L
Replace the seal in the housing prior to reassembly. Refer to
page 11 for seal replacement instructions.
Lip Seal RemovalLip Seal Replacement
Axle Mounting Horn Removal
Using a 1/2 inch wrench (or socket) remove the four
fasteners (4 bolts used on one assembly - 3 bolts and 1 nut
used on the other side) securing the assembly to the main
housing.
Make note or mark the orientation of the axle mounting horn
before removal.
Remove the axle mounting horn assembly and two washers
from the axle.
Pack Pocket Area with Grease and Install Washers
Fill the washer pocket area with Rykon Premium Grease or
an equivalent product.
Install washer aligning notches with ribs in pocket of main
housing. Install washer on top of “notched" washer.
Install O-ring onto axle mounting horn assembly.
Axle Mounting Horn Components
210-3010L
www.mymowerparts.com
Page 15
Page 16
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
210-3010L
Axle Mounting Horn Assembly
Use caution while installing the replacement axle mounting
horn assembly to avoid damaging the new seal. Make sure
the notches in the washer remain engaged to the tabs in the
mounting horn assembly during installation. Rotate the axle
as you are installing the assembly to allow the splined end
of the axle to engage into the splined gears of the differential
assembly. When properly aligned it should slide in freely and
the axle horn should seat down onto the main housing and
engage into an anti-rotational slot.
Minor Repairs
Remove the filter and allow the oil to drain from the transaxle
housing.
Remove the two internal hex head screws retaining the filter
base to the axle housing.
Remove the filter base and gasket.
Unscrew the filter base from the 7/16 SAE barbed fitting and
hose.
NOTE: It is recommended to not remove the hose from the
barbed fitting while changing filter bases.
Screw the new filter base onto the 7/16 SAE barbed fitting
and hose. Torque the fitting to 4 - 6 ft. lbs. (5.4-8 Nm).
Install the filter base and a new gasket with the two screws
and torque the screws to 7 -10 ft. lbs. (9.5-13.5 Nm).
Install Axle Horn
Install four new fasteners or apply Locktite #242 (or equivalent) to the original fasteners and torque to 13-15 ft. lbs.
(17.6-20 Nm).
Filter Base Replacement
NOTE: Not all models have the filter base mounted to the
transaxle so these procedures may not apply to your vehicle.
Refer to your vehicle manual.
Replacement of the filter base or filter base gasket can be
accomplished with the transaxle still in the vehicle in many
cases, but will require draining the oil from the transaxle.
Filter Base Removal
Filter Base Components
Page 16
210-3010L
www.mymowerparts.com
Page 17
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
Minor Repairs
Primary Component Replacement
Once it has been determined through troubleshooting that
either the BDU-10L or the 210-3000 is defective, the defective component must be replaced following the procedures
outlined in this section.
Remove the transaxle from its installed location and remove
any external components such as a cooling fan and input
pulley or frame mounting hardware.
Remove the oil lines (hoses and fittings) and the oil filter from
the transaxle so that as much oil as possible can be drained
from the housings.
NOTE: Hoses may have to be removed from some fittings
in various models. If hoses are removed from the fittings,
new hoses and fittings will be necessary during reassembly
to prevent leaks and possible failure.
The oil lines and fittings must be replaced if damaged in any
way.
210-3010L
Remove Four Mounting Bolts
The BDU-10L should slide freely away from the 210-3000. If
necessary you may carefully pry the two components apart
by applying pressure with a long straight blade screw driver.
Oil Lines, Fittings and Filter Removal
Using 1/2 inch wrench (and/or socket) remove four mounting
bolts holding the BDU-10L transmission in position on the
210-3000 axle assembly. One location uses a “lock-nut”
also.
Use caution to avoid damaging either component.
Remove BDU From Axle Assembly
210-3010L
Page 17
www.mymowerparts.com
Page 18
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
210-3010L
Primary Component Replacement
An o-ring and a quad ring are used to seal between the two
components. These are to be replaced with new parts during
reassembly.
NOTE: The quad ring is used on the through shaft version
only.
Minor Repairs
Install the BDU-10L, aligning the splined shaft ends with the
splined coupling and splined input pinion gear of the 210-
3000. The two shafts should slide freely into place or damage
could occur. Do not force the BDU-10L down. If they do not
slide together freely, remove it and try again.
Alignment of splines may be accomplished by rotating the
brake disc and the input shaft.
Install the four bolts (and one nut) and torque to 13-15 ft.lbs.
(17.6-20 Nm).
Primary Components and Assembly Hardware
Installation of the BDU-10L onto the 210-3000 will be easiest
with the BDU mounting surface positioned facing up.
Place a new O-ring and new quad-ring into position on the
210-3000.
BDU-10L Installation
Install the oil lines and fittings.
Fill with oil as described in the Maintenance section covering
oil and filter change.
210-3000 Positioned for Reassembly
Page 18
www.mymowerparts.com
210-3010L
Page 19
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
Major Repairs
Major Repairs
General Information
Major Repairs described in the following sections are for the
complete disassembly and reassembly (Major Repair) of the
210-3010L Transaxle and will void all product warranty,
unless license to perform said Major Repairs was previously
obtained from an Authorized Representative of HYDROGEAR.
Cleanliness is a primary means of assuring satisfactory life
on repaired units. Cleaning parts by using solvent wash and
air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign materials and
chemicals.
Protect all exposed sealing surfaces and open cavities from
damage and foreign material. The outer surfaces should be
cleaned before beginning any repairs.
It is recommended that all O-rings and seals be replaced.
Lightly lubricate all O-rings and seals with a clean petroleum
jelly prior to assembly.
It is recommended that parts requiring replacement be
replaced with the complete assembly (kit) as shown in the
Service Parts Drawings on pages 32-35.
210-3010L
Remove the oil lines (hoses and fittings) and the oil filter from
the transaxle as described in the Minor Repair section so that
as much oil as possible can be drained from the housings.
Remove the BDU-10L transmission as described in the
Minor Repair section.
Remove the parking brake components as described in the
Maintenance section.
Remove the axle carrier mounting horns as described in the
Minor Repair section. Make note of the orientation or mark
the mounting horn before removal.
210-3000 Disassembly Procedures
Position the left hand housing assembly with the BDU-10L
mounting surface down (Take care to avoid damage to the
axle carrier assembly mounting surface). This places the
right hand housing assembly up and allows access to the
housing assembly bolts.
Prior to performing Major Repairs on the 210-3010L Hydrostatic Transaxle, remove the transaxle from its installed
location and remove any external components such as a
cooling fan and input pulley or frame mounting hardware.
NOTE: Thoroughly clean all exposed surfaces prior to any
further disassembly.
210-3010L
Remove Axle Assembly Bolts
Page 19
www.mymowerparts.com
Page 20
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
210-3010L
210-3000 Disassembly Procedures
Using 1/2 inch wrench (and/or socket) remove two torque
strap mounting bolts and locknuts from the housing end
opposite from the differential (front).
Using 1/2 inch wrench (and/or socket) remove the eleven
housing assembly bolts.
Separate the two housing halves by applying pressure (as
shown) with two large straight blade screw drivers. Use
caution to prevent damage to the mating sealing surfaces as
you separate the housings. The sealant will make it difficult
to separate the two halves.
Major Repairs
Left Hand Housing and Components
Final Drive Pinion Assembly
Separating Housing Halves
It may be necessary to tap lightly on the exposed end of the
brake shaft assembly as the housings are being separated
so that it remains in the left hand housing (lower half).
Remove the final drive pinion assembly and washer.
Inspect the teeth (internal and external) for damage or
unusual wear and replace as necessary.
Inspect the bearing surfaces of the shaft for damage or
unusual wear. If the shaft is found to need replacing the
mating parts may also require replacement.
Inspect the washers for unusual wear.
Replacement of complete assemblies is recommended.
Page 20
Removal of Final Drive Pinion
210-3010L
www.mymowerparts.com
Page 21
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
Major Repairs
Differential Assembly
Remove the differential assembly and triangular washer
from the housing.
Inspect the 60t gear teeth for damage or unusual wear.
Inspect the 10t planet gears for damage or unusual wear. Roll
the gears to check for proper operation.
Inspect the axle bore in the 60t gear and the axle bore in the
end cap for unusual wear.
Check the bolts for proper torque of 25-32 ft.lbs.
(34-43 Nm).
If damage or unusual wear is found in any of the components,
replacement of the entire assembly is recommended.
210-3010L
Inspect the internal splines of the reduction gear and the
splines on the jack shaft for wear.
Inspect the bearing surfaces at the end of the jack shaft for
damage or unusual wear, if the shaft is found to need
replacing, the mating parts may also require replacement.
Inspect the brake shaft bearings and the coupling for
damage or unusual wear and replace as necessary.
NOTE: The coupling is designed as a press fit onto the shaft.
Over time the splines may wear and the coupling will become
loose. If the coupling is not a press fit onto the brake shaft,
replacement is recommended.
Inspect the washers for unusual wear.
Replacement of complete assemblies is recommended.
Removal of Differential Assembly
Differential Assembly
Reduction Gear/Jack Shaft & Brake Shaft Assembly
It may be necessary to remove these assemblies at the
same time because of an overlapping condition (only if the
jack shaft will not pull out of the reduction gear freely).
Inspect gear teeth for damage or unusal wear.
Removal of Reduction Gear and Brake Shafts
Reduction Gear and Brake Shaft
210-3010L
Page 21
www.mymowerparts.com
Page 22
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
210-3010L
210-3000 Disassembly Procedures
Input Shaft Assembly
(Not used in all models)
Removal of the input shaft assembly will require applying
pressure onto the end of each bearing retainer while lifting
the assembly from the housing (the top bearing retainer has
a wave style spring washer in it to make up any end play).
The use of gasket sealant in this area may make it difficult
to remove this assembly without the use of a pry tool (as
shown).
Inspect each component for damage or unusual wear and
replace as necessary.
Major Repairs
Input Shaft and Input Pinion Components
Housing Assemblies (Left & Right)
Inspect both housing assemblies and bearings for damage.
Replacement of complete assemblies will be necessary if
any damage is present.
Removal of Input Shaft Assembly
Input Pinion Removal
Input Pinion Assembly
(Not used in all models)
The input pinion assembly may be pressed out of the
housing for inspection of the gear teeth and the bearing.
Replacement of the assembly is recommended if any unusal
wear or damage is found.
Left and Right Housing Assemblies
Axle Assembly Components
Page 22
210-3010L
www.mymowerparts.com
Page 23
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
Major Repairs
Reconditioning and Replacement of Parts
After disassembly, all parts should be thoroughly cleaned in
a suitable solvent.
All sealant material must be cleaned from the housing halves
prior to beginning any reassembly.
Inspect all parts for damage, nicks or unusal wear patterns.
Replace all parts having unusual or excessive wear or
discoloration.
Inspect the sealing surfaces, bearing surfaces and shaft
splines. Polish the sealing areas on the shafts if necessary.
Replace any worn or damaged parts.
Clean and lightly lubricate parts prior to assembly.
Replace all o-rings, gaskets and shaft seals.
Be sure to torque all threaded parts to the recommended
torque levels.
210-3010L
Housing Positioned For Re-assembly
Differential Assembly
Position the triangular washer (tabs pointing up) over the axle
end.
Install the differential assembly onto the axle end. The
assembly should slide freely into place when the splines are
properly aligned.
Assembly Procedures
Install a new lip seal in the left hand housing assembly and
install the left hand axle mounting horn assembly onto the
left hand housing assembly as described in the minor repairs
section. Be sure the orientation of the mounting horn is the
same as before it was removed.
Position the left hand housing assembly with the axle
mounting horn pointing down.
Install Differential Assembly
Reduction Gear/Jack Shaft & Brake Shaft Assembly
Install the brake shaft assembly (coupling end down).
To install the reduction gear/jackshaft it will be necessary to
position the reduction gear and one washer (below the
reduction gear) then slide the jack shaft through them and
into position.
Install Axle Horn
210-3010L
Install the second washer on top of the reduction gear.
Page 23
www.mymowerparts.com
Page 24
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
210-3010L
210-3000 Assembly Procedures
Reduction Gear/Jack Shaft & Brake Shaft Assembly
If the jack shaft does not slide through the reduction gear
freely it will be necessary to install them simultaneously with
the brake shaft assembly.
Install Reduction Gear and Brake Shaft Assembly
Major Repairs
Install Input Pinion
Input Shaft Assembly
NOTE: Prior to assembling of the input shaft components be
sure all old gasket material is cleaned from the bearing
retainers.
Install a new lip seal into the upper bearing retainer.
Final Drive Pinion Assembly
Install the pinion assembly and washer into position (washer
on top).
Install Final Drive Pinion
Input Pinion Assembly
Install new o-rings (quad rings) onto each bearing retainer.
NOTE: There have been two styles of bearing retainers
used. One style hase a machined groove for an o-ring while
the other does not have a groove and requires a "quad" ring.
Use of the correct ring is necessary to properly seal the
assembly.
Wrap the splines and threads of the input shaft with cellophane (or equivalent) to protect the lip seal from damage.
Install the wave washer into the upper bearing retainer and
install the bearing retainer onto the input shaft assembly.
Remove the cellophane.
Place the input shaft assembly into the lower bearing
retainer.
NOTE: The bearing retainers are reversible and interchangeable. Take care to position both so that the input shaft is
aligned with the center of the input pinion assembly. Because of the high rpm that these assemblies will run, any
misassembly will cause very noisy operation and rapid
failure.
Install the input pinion assembly into the housing. The
bearing should require very little force to install properly.
Make sure the gear and bearing roll freely.
Page 24
www.mymowerparts.com
210-3010L
Page 25
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
Major Repairs
Before installing the input shaft assembly, apply a small
amount of the liquid gasket sealant in the recessed pocket
of the left hand housing where the o-ring on the upper bearing
retainer will be positioned.
210-3010L
Sealant Application
NOTE: Prior to applying new sealant the old sealant must be
cleaned from all surfaces.
Position the right hand housing assembly and apply the
liquid gasket onto the housing face. A small bead of the
sealant around the outer part of the housing face will be
sufficient. The line art indicates the correct areas.
NOTE: A small recess on the right hand housing face is
designed to catch a limited amount of sealant as it is
squeezed out from between the housings during assembly.
This area improves the sealing of the housing but, excessive
sealant could contaminate the transaxle assembly. Use
sparingly.
Input Assembly Sealant Application
Apply pressure onto the outer end of each bearing retainer to
compress the wave washer and install the complete assembly into the pockets of the housing while aligning the notches
in the bearing retainers with the tabs in the housing.
Sealant Application for Models with Input Shaft
Install Input AssemblySealant Application for Models without Input Shaft
210-3010L
Page 25
www.mymowerparts.com
Page 26
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
210-3010L
210-3000 Assembly Procedures
Housing Halves Assembly
With the sealant applied, install the right hand housing down
onto the left hand housing while aligning the various shafts
with the bearings. Make sure the aligning pins for the housing
halves engage properly and seat the right hand housing
firmly onto the left.
Apply a locking adhesive and install the eleven primary
assembly bolts.
Following the pattern illustrated in the line art, torque each
bolt to 16-21 ft.lbs. (21.6-28.5 Nm).
7
2
9
11
13
Major Repairs
Install a new lip seal onto the brake shaft as described in the
Minor Repairs section.
Lip Seal Installation
5
12
3
10
Recomended Bolt Torque Sequence
Install the two “torque strap mounting” bolts and locknuts.
Torque each to 13-17 ft.lbs. (17.6-23 Nm).
NOTE: Always use care during assembly procedures to
avoid damage to lip seals.
Install a new lip seal into the right hand housing axle bore and
install the right hand axle mounting horn assembly as
described in the Minor Repairs section.
6
8
4
1
Roll the gears to insure the proper assembly and function of
the unit.
Page 26
210-3010L
www.mymowerparts.com
Page 27
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
Major Repairs
BDU-10L Disassembly Procedures
Prior to performing major repairs on the BDU-10L remove the
external components as described in the Minor Repairs
section of this manual. These include the following:
Using a 6mm internal hex wrench, remove the eight screws
which retain the center section to the housing.
210-3010L
Remove the pump cylinder block kit from the pump shaft.
Inspect the splines on the shaft and in the pump block for
damage or excessive wear. Check the pistons and block
bores for excessive wear. The pistons should fit with very
little side clearance in the block bores, but must slide freely.
Note: The correct bore diameter for the 10cc cylinder block
is 0.6295" to 0.6303". The 10cc piston should be 0.6288" to
0.6291" diameter.
Remove the pump cylinder block spring and thrust washer
from the pump shaft.
Remove the motor cylinder block kit and shaft assembly
from the housing. Check the pistons and block bores for
excessive wear. The pistons should fit with very little side
clearance in the block bores, but must slide freely. Inspect
the splines for damage or unusual wear. Replacement of the
complete assembly is recommended if damage or excessive wear is found.
Center Section Removal
The internal springs of the pistons should separate the
center section from the housing. Remove the center section
from the housing.
CAUTION: The cylinder block may stick to the surface of
the center section. Exercise caution to prevent damage
to the components.
Remove the gasket and two aligning pins from the housing.
The gasket will not be reusable.
Remove Cylinder Blocks
Aligning Pins and GasketCylinder Block Components
210-3010L
www.mymowerparts.com
Page 27
Page 28
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
210-3010L
BDU-10L Disassembly Procedures
Remove the swashplate assembly and cradle bearings from
the housing. Inspect the cradle bearings for wear to the low
friction coating. Inspect the swashplate and bearing for any
unusual wear or damage. If damage to the swashplate or
cradle bearings is found, inspect the housing for possible
damage. Replace complete assemblies as necessary.
Remove the slot guide block from the displacement control
shaft.
Remove the motor thrust bearing from the housing.
Remove the input shaft lip seal retaining ring.
Pull the lip seal out of the housing bore. A hook type tool may
be used to pry the seal out. Care must be taken to avoid
damage to the housing bore, shaft sealing surface or
bearing. Once removed, the seal is not reusable.
Remove the bearing spacer washer.
Remove the pump shaft assembly from the housing.
Inspect the splines on the shaft for damage or unusual wear.
Inspect the bearing. Replacement of the assembly is recommended if any damage or excessive wear is found.
Major Repairs
Remove the displacement control shaft lip seal from the
housing. Care must be taken to avoid damage to the housing
bore.
Housing, Control Arm and Lip Seal
Inspect the housing for damage.
Inspect the control shaft journal bearing for excessive wear.
The bearing should be 0.4722" to 0.4733".
Inspect the housing motor shaft journal bearing for excessive wear. The bearing should be 0.4961" to 0.4998".
Pump/Input Shaft Assembly
Remove the displacement control shaft from the housing.
If excessive wear or damage was found, replace the complete housing assembly.
Inspect the center section for damage to the cylinder block
running surfaces.
Inspect the center section pump shaft journal bearing for
excessive wear. The bearing should be 0.4961" to 0.4998".
Inspect the center section motor shaft needle bearing for
damage.
If excessive wear or damage was found, replace the complete center section assembly.
Page 28
210-3010L
www.mymowerparts.com
Page 29
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
Major Repairs
Reconditioning and Replacement of Parts
After disassembly, all parts should be thoroughly cleaned in
a suitable solvent.
Inspect all parts for damage, nicks or unusal wear patterns.
Replace all parts having unusual or excessive wear or
discoloration.
Inspect the sealing surfaces, bearing surfaces and shaft
splines. Polish the sealing areas on the shafts if necessary.
Replace any worn or damaged parts.
The running surfaces of the cylinder blocks MUST be flat and
free from scratches. If scratches or wear are found on the
running surface of the cylinder block or center section,
replace the parts.
BDU-10L Assembly Procedures
Clean and lightly oil parts prior to assembly of the BDU-10L
transmission.
210-3010L
Control Arm Installation
Install the displacement control shaft.
Be sure to torque all threaded parts to the recommended
torque levels.
Replace all o-rings, gaskets and shaft seals.
CAUTION: Most parts have critical high tolerance surfaces. Care must be exercised to prevent damage to
these surfaces during assembly. Protect all exposed
surfaces, openings and ports from damage or foreign
material.
Install the pump shaft assembly into the housing.
Shaft Installation
210-3010L
Page 29
www.mymowerparts.com
Page 30
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
210-3010L
BDU-10L Assembly Procedures
Install the bearing spacer washer.
Install the lip seal and retaining ring as described in the Minor
Repair section.
Install the cradle bearings.
Install the slot guide block onto the displacement control
shaft.
Major Repairs
Hold the swashplate in position and measure the end play of
the displacement control shaft using a dial indicator or a
depth guage. Using a suitable sleeve, press the control shaft
bearing into the housing until the control shaft end play is
between 0.020" and 0.060" (.508-1.5 mm).
Install the thrust washer and pump cylinder block spring onto
the pump shaft.
Install Swashplate
Install the swashplate into the housing. The slot on the
swashplate must engage the slot guide block on the displacement control shaft. Use a tool such as a screwdriver or
scribe to hold the guide block in position while installing the
swashplate.
Measure Control Arm End PlaySwashplate Kit Components
Install the springs, piston washers and pistons into the
cylinder block. The pistons must move freely in their bores.
Cylinder Block Kit
Page 30
210-3010L
www.mymowerparts.com
Page 31
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
Major Repairs
NOTE: To simplify the installation of both the motor block
and the pump block kits, wrap a rubber band snuggly around
the pistons. This is intended to hold the pistons in their bores
as the block kits are handled during installation.
210-3010L
Install the motor shaft/cylinder block kit. Use caution to
prevent damage to the journal bearing while guiding the shaft
into position. Once installed, it will be necessary to hold the
assembly in position until the center section has been
installed.
Cylinder Block Kit with Rubber Band
With the swashplate in the “neutral” (0 angle) position and the
transmission housing laying on its side, install the pump
cylinder block kit onto the pump shaft in the housing.
Install the motor thrust bearing into the housing.
Install Motor Shaft Kit
NOTE: It will be necessary to have a Dry journal bearing to
prevent a hydraulic lock while installing the motor shaft kit.
Install Center Section
Check to see that the piston springs are centered in the
cylinder block bores. If necessary, position them with a
small screwdriver.
Position the housing with the housing opening UP, and install
the two aligning pins and new gasket onto the housing.
Lubricate the running surfaces of the cylinder blocks and the
center section.
Install the center section onto the housing. While holding the
motor shaft in position in the housing journal bearing.
CAUTION: Make sure all parts are properly aligned. Do
not use excessive force.
Install the eight bolts and torque evenly to 12-15 ft.lbs.
(16-20 Nm).
Rotate the shafts a minimum of two turns to assure correct
assembly. When properly assembled the shafts should
require minimal torque to turn, approximately 15 in.lbs. (1.7
Nm).
Refer to the Minor Repair section of this manual to complete
reassembly of the BDU transmission.
210-3010L
Page 31
www.mymowerparts.com
Page 32
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
210-3010L
*
*
46
44
40
39
38
*
93
*
41
47
35
*
*
43
36
33
42
72
72
45
2
99
78
37
37
210-3010L PARTS DRAWING
20
123
22
21
95
63
7
73
63
48
70
65
75
BREATHERS
*
94
103
*
*
94
122
97
98
92
32
31
78
62
28
31
32
16
69
64
67
69
12
77
76
7
22
21
1
71
8
68
85
88
10
11
91
9
74
89
123
20
87
84
101
81
SEAL KIT: #7(2), 8, 10, 32(2), 68 AND 78(2).
102
Page 32
www.mymowerparts.com
96
38
82
92
82
82
210-3010L
Page 33
Hydro Gear Parts or New Units Call 606-678-9623 or 606-561-4983
210-3010L210-3010L PARTS LIST
PARTS LIST
NO.DESCRIPTIONNO.DESCRIPTION
1LH HSG ASSEMBLY70WASHER, 7/8 ID X 1-1/2 OD
2RH HSG ASSEMBLY71HEX BOLT, 5/16-18 X 3-1/2
7OIL SEAL, .984 X 1.5 X .2572HEX LOCK NUT 5/16-18
8QUAD RING73HEX BOLT, 5 /16-18 X 1-1/2
9CAP SCREW, 1/4-20 X 174HEX BOLT 5/16-18 X 1
10GASKET, FILTER BASE75DIFFERENTIAL WASHER
11FILTER BASE ASSEMBLY76SHOULDER BOLT
12PINION ASSEMBLY77FREEWHEEL ACTUATING ARM,
16BRAKE SHAFT ASSEMBLY78OIL SEAL .625 X 1.0 X .25
20AXLE MOUNTING HORN ASSEMBLY81HEX BOLT 5/16-18 X 1-3/4
21WASHER, 1.0 X 1.63 X .0882HEX BOLT 5/16-18 X 4-1/2
22WASHER, 1.0 X 2.06 X .0984SAE PORT STRAIGHT FITTING 7/8
28INPUT ASSEMBLY85SAE PORT STRAIGHT FITTING 7/16
31BEARING RETAINER87HOSE, 8-1/2" LONG
32O RING, 2-1/2 OD88HOSE, 10-1/2" LONG
33ASSEMBLY, BRAKE YOKE89SPIN-ON FILTER
35ARM, BRAKE91TRANSMISSION
36PLATE, PUCK92WIRE RETAINING RING
37PUCK, BRAKE93BRACKET
38WASHER, 7/16 X 7/8 OD X .06094BREATHER
39NUT, CASTLE 5/16-2495PLUG, STRAIGHT THREAD
40COTTER PIN96FITTING
41BRAKE ACTUATING PIN97WASHER
42HI-PRO KEY, 3/16 X 5/898PULLEY
43TORSION SPRING SPACER99WASHER, 5/16 ID X 9/16 OD
44WASHER, 7/8 OD X .260 ID101 STRAIGHT SEA 7/8 FITTING