Char-Lynn

®

Power Steering

Repair Information

August, 1999

110, 230 and 450 Series

Steering Control Units 001 002

110, 230, and 450 Series Steering Control Units

Cast

End

Cap

1

2

O-ring Groove

3

O-ring Groove

Low Input Torque

Spring (4)/Spacer (2)

Package

12

11

11

U

Previous Manual

Steering Check Valve

V

W

X

Y Z 4

7 3

Standard Input Torque

Spring (6)

Package

11

6

23

9

22

3

5

9 8

31

13

14 13

17

15

18

19

16

30

10

Special Tools Available

600057-000 Spring Installation Tool

5422-000 12 Point Drive Socket ( 5/16 in.) — -001

64489-000 6 Point (E10) Torx Drive Socket ( 5/16 in.) — -002

Note: Current -002 uses a Hex Head bolt – 1/2 inch across flats

See Note Below (lower right)

Cap Screws 12 Pt. Drive No. 5389-XXX, Spacer Plate 7970, and End

Cap, 8438 are -001 Parts. If any one of these parts needs replacing, order

Kit listed in chart (below) by displacement. Kit parts will update your steering control unit to -002 design level.

Note: When installing kit parts, gerotor outer ring will have to be turned

so the o-ring groove faces the end cap (gerotor star—if the spline is full

length ring and star can be turned together, but if star has a

partial spline turn ring only, this partial splined star must

remain unturned). Replacement spacer plate will have a

o-ring groove, position this groove toward gerotor.

Note: All housing valves are factory adjusted on assembled units to a code designation and are not to be changed. This housing (with specified valve pressure settings), the mating spool, and the sleeve are not practical replacement parts.

Ref.

No.

Description

1 Cap Screw, Hex Head

2 Cap, End

3 Seal, 72,6 mm [2.86 in.] ID

4 Gerotor

5 Spacer

6 Plate, Spacer

7 Drive

8 Housing

9 Sleeve, Control/Spool, Control

10 Pin, Centering

Ref.

No.

Description

11

12

Spring, Centering

Spring, Spacer

13 Bearing Race

14 Bearing, Needle Thrust

15 Seal, 47,2 mm [1.86 in.] ID

16 Seal, 24,9 mm [.98 in.] ID

17 Seal, Quad Ring, 26,7 mm [1.05 in.] ID

18 Bushing, Seal Gland

19 Ring, Retaining

22 Ball, 6,35 mm [.250 in.] OD

Ref.

No.

Description

23 Pin, Roll, 34,92 mm [1.375 in.] Length

30

W

X

Ball, Check

31 Pin, Roll, 40,00 mm [1.575 in.] Length

U Retainer, Check Ball

V Ball, Check

Seal — 7,6 mm [.30 in.] ID

Seat, Check Ball

Y Seal — 9,2 mm [.36 in.] ID

Z Screw, Set

2

110, 230, and 450 Series Steering Control Units

Tools required for disassembly and reassembly.

— Screwdriver (102-152 mm [4 in. - 6 in.] long, x 3 mm [118 in.] wide flat blade).

— 6 Point (E10) Drive part No. 64489-000* or 1/2 inch socket for current hex head cap screws.

— Breaker bar wrench.

— Torque wrench (30 Nm [275 lb-in] capacity).

— Plastic hammer or rubber hammer.

— 1/4 inch Hex key.

— #10-24 machine screw, 38 mm [1-1/2 in.] long.

— Needle nose pliers.

The following tool is not necessary for disassembly and reassembly, but is extremely helpful.

Spring installation tool 600057 *

* Tools available—by special order—through our service department.

3

4

110, 230, and 450 Series Steering Control Units

Disassembly

Cleanliness is extremely important when repairing a steering control unit. Work in a clean area. Before disconnecting lines, clean port area of unit thoroughly. Use a wire brush to remove foreign material and debris from around exterior joints of the unit.

Although not all drawings show the unit in a vise, we recommend that you keep the unit in a vise during disassembly. Follow the clamping procedures explained throughout the manual.

Gerotor (Meter) End

2 Remove 5/6 in. cap screws and sealing washers, if used.

3 Remove end cap.

4 Remove seal.

Meter (Gerotor)

Seal Groove this Side

-002 Unit.

See Note

Inside Front

Cover (Page 2)

Seal

25 mm

[1 inch]

Max.

-002 Steering

Control Unit with 6 Point

(E10) Drive Screws or Current Hex

Head Screws

Spacer

Figure 3

Figure 1

1 Clamp unit in vise, meter end up. Clamp lightly on edges of port face sides (see figure 1). Use protective material on vise jaws.

Housing distortion could result if jaws are overtightened.

Seal washers are not used with 6 point (E10) drive

screws or current hex head screws and -002 end cap

(-002 end cap does NOT have the o-ring groove)

5 Remove meter. Be careful not to drop star.

6 Remove seal.

7 Remove drive spacer. Spacer is not used on some models. Refer to Parts Information No. 6-321 to determine if spacer is used on your particular model.

Drive

O-ring Groove this Side -002

Unit — Old

Spacer Plate has No O-ring

Groove

Spacer Plate

Cap Screw

Seal

Seal

Figure 2

Figure 4

8 Remove drive.

9 Remove spacer plate.

10 Remove seal from housing.

11 Remove housing from vise.

110, 230, and 450 Series Steering Control Units

Disassembly

Manual Steering Check

Valve (when applicable)

Ball

Roll Pin

Early Units * Built with these Parts

Spring

Retainer Plug

Ball

Low Input

Torque

Steering

Control

Units

Spring

Spacers (2)

Roll Pin

Ball

* Anti-Cavitation Valves for Cylinder Ports

Figure 5

12 Carefully remove anti-cavitation valves and manual steering check valve (roll pin and ball – if applicable) from bolt holes by tipping housing as shown (see figure 5).

Control End

Springs (4)

Replacement

Teflon Seal (1 Piece)

Special Seal Gland Marked with Groove for Identification

Standard Input

Torque

Steering

Control

Units

Old 3 Piece

Teflon Seal

Dust Seal

Dust Seal

Figure 6

13 Place housing on clean soft cloth, gerotor end down, to protect surface finish. Use thin bladed screwdriver to pry retaining ring from housing, as shown in figure 6.

Seal Gland Bushing

Figure 7

14 Lift spool and sleeve assembly up just far enough to free gland bushing from housing (figure 7). Remove bushing.

Springs (6)

Quad Ring Seal

Standard Seal

Gland Not Marked with Groove (Special Seal

Gland Shown with Groove Above)

Figure 8

Note: Examine bushing to determine whether you are repairing low torque or standard torque unit. Low torque unit has grooves on seal gland bushing while standard torque unit has no grooves on bushing.

Seal gland bushings for low input torque and standard torque units are not interchangeable (see figure 8).

15 Low Input Torque Units: Remove back-up ring, o-ring and Teflon seal from seal gland bushing. Standard Input Torque Units: Remove quad ring seal from seal gland bushing.

16 Use thin bladed screwdriver to pry dust seal from seal gland bushing. Do not damage bushing.

5

110, 230, and 450 Series Steering Control Units

Disassembly

Bearing Race

Seal

Needle Thrust Bearing

Standard Input Torque

Low Input Torque

Spring/Spacer Package

Figure 9

17 Remove two bearing races and needle thrust bearing and seal from spool and sleeve assembly.

Figure 11

Pin

19 Push pin from spool and sleeve assembly.

20 Push spool partially from control end of sleeve, then carefully remove centering springs from spool by hand (Figure 11). Low input torque unit uses four centering springs and two spacers. Standard input torque unit uses six centering springs.

21 Remove seal from housing (see figure 12).

22 Remove manual steering check valve from housing (when applicable) by removing set screw with 1/4 in. hex key.

Manual Steering

Check Valve –

Early Design

Shown Here

Warning: Pin may slide outward from spool and sleeve locking these parts into housing, please follow instructions.

6

Figure 10

18 Tip housing onto port face. Remove spool and sleeve assembly from 14 hole end of housing (Figure 10).

Attention: Do not bind spool and sleeve in housing. Rotate spool and sleeve assembly slowly when removing it from housing.

O-ring 7,7 mm [.30 in.] ID

Set Screw

Check Ball Retainer

Check Ball

Check Ball Seat

O-ring 9,3 mm [.36 in.] ID

Figure 12

110, 230, and 450 Series Steering Control Units

Disassembly/Reassembly

23 Screw a #10-24 machine screw into end of check ball seat. Then lift seat out of housing by pulling on screw with pliers.

24 Remove two seals from check valve seat.

25 Tip housing to remove check ball and check ball retainer.

26 Do not remove any valves other than manual steering check valve assembly and anti-cavitation valve assembly. All other valves are factory preset and are non-serviceable.

Reassembly

Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leakage. Clean all metal parts in clean solvent.

Blow dry with air. Do not wipe dry with cloth or paper towel because lint or other matter can get into the hydraulic system and cause damage. Do not use grit paper or file or grind these parts.

Note: Lubricate all seals with clean petroleum jelly (Vaseline). A good service policy is to replace all old seals with new seals. Do not use excessive lubricant on seals for meter section.

Refer to parts lists covering your steering control unit when ordering replacement parts.

Spring Slot

Input Shaft End

Control Sleeve

Assemble

Input Shaft

End First

Control Spool

Identification Marks

Figure 14

Control End

You may skip steps 1 through 5 if the early design manual steering check valve does not apply in the unit you are servicing.

6 Assemble spool and sleeve carefully so that spring slots line up at the same end. Rotate spool while sliding parts together. Some spool and sleeve sets have identification marks; align these marks as shown in figure 14. Test for free rotation. Spool should rotate smoothly in sleeve with fingertip force applied at splined end. Align spring slots in spool and sleeve and stand parts on end of bench.

Manual Steering

Check Valve –

Early Design

Shown Here

Set Screw

O-ring

9,3 mm

[.36 in.] ID

O-ring

7,7 mm

[.30 in.] ID

Check Ball Seat

Check Ball

Check Ball Retainer

Standard Torque

Low Torque

Spring Spacers (2)

Figure 13

1 Use a needle nose pliers to lower check ball retainer into check valve hole in housing (when applicable). Make sure retainer is straight in housing (not tilted on edge – see figure 13).

2 Install check ball in housing.

3 Lubricate 9,2 mm [.36 in.] ID seal and 7,6 mm [.30 inch] ID seals.

Install seals on check ball seat as shown in figure 13.

4 Lubricate check ball seat and seals thoroughly before installing seat in housing. When installing seat do not twist or damage seals.

Install check ball seat in housing, inserting open end of seat first

(figure 13). Push check ball seat to shoulder of hole.

5 Install set screw. Use a 1/4 in. hex key to torque set screw to 11

Nm [100 lb-in] maximum. To prevent interference, make sure top of set screw is slightly below housing mounting surface.

Figure 15

7 Centering Springs for Low Input Torque Units: Low input torque units use four centering springs with two spring spacers in the center, as shown in Figure 15.

Centering Springs for Standard Input Torque Units:

Standard input torque units use six centering springs, as shown in figure 15. Insert spring installation tool (PartNo. 600057) through

7

110, 230, and 450 Series Steering Control Units

Disassembly

12 Place housing on clean lint free colth. Install 47,2 mm [1.86 in.] ID seal in housing (figure 18).

spring slots of spool and sleeve. Position centering springs on bench so that extended edge is down and arched center section is together

(figure 15). Next, with spring notches facing sleeve, insert one end of entire spring set into spring installation tool.

8 Compress extended end of centering spring set and push into spool and sleeve assembly. Keep pressure on spring ends while withdrawing installation tool and pushing forward on springs at same time.

9 Center spring set in spring slots. Seat springs down evenly and flush with upper surface of spool and sleeve.

Bearing Race

Seal

Needle Thrust Bearing

Pin

Figure 16

10 Insert pin through spool and sleeve assembly until pin is flush at both sides of sleeve.

Figure 18

13 Install two bearing races and needle thrust bearing as shown in figure 18.

14 Install 24,9 mm [.98 in.] lD dust seal in seal gland bushing, with smooth side of seal facing down towards bushing (see figure 19).

15 Low Input Torque Units: Lightly Iubricate seal before installation.

Install Teflon seal (see figure 20).

Standard Input Torque Units: Install quad ring seal in seal gland bushing. Smooth seal in place with finger. Do not use any seal that falls freely into pocket of bushing.

Retaining Ring

Dust Seal

Seal Gland

Bushing

(with seals)

Large Socket

Figure 17

8

11 Position spool and sleeve assembly so that splined end of spool enters 14 hole end of housing first (figure 17).

Attention: While inserting spool and sleeve assembly into housing, make sure parts do not tilt out of position. Push assembly gently into place with slight rotating action, keeping pin nearly horizontal.

Bring spool assembly entirely within housing bore until parts are flush atl 4 hole end of housing. To prevent cross pin from dropping into discharge groove of housing, do not pull spool assembly beyond this point. With spool assembly in this flush position, check for free rotation within housing by turning assembly with fingertip force at splined end.

Figure 19

16 Install seal gland bushing over spool end with twisting motion.

Tap bushing in place, use a large socket (see figure 19)and a rubber hammer. Make sure bushing is flush against bearing race.

110, 230, and 450 Series Steering Control Units

Reassembly

Standard Torque

Screwdriver

Dust Seal

Retaining

Ring

Seal Gland

Bushing

Quad Ring

Seal

Seal

Low Torque *

Teflon Seal

Roll Pin (2)

40,00 mm

[1.575 in.] L

Ball (2)

4,762 mm

[.1875 in.] OD

Bushing with

Identification

* Anti-Cavitation Valves for Cylinder Ports

Groove

Early Units * Built with these Parts

Spring

Retainer Plug

Ball

O-ring Groove this

Side -002 Unit —

Old Spacer Plate has No O-ring

Groove

Manual Steering

Check Valve

(when applicable)

Seal

Roll Pin (1)

34,92 mm

[1.375 in.] L

Ball 6,35 mm

[.250 in.] OD

*

Low Input Torque Seal Package — One Piece Teflon

Seal use on -002 Unit and is Replacement Seal for 3

Piece Seal on Older Low Input Torque Units.

3 Piece

Seal

1 Piece

Seal

Figure 22

Cross Section of Old and New Seal

Figure 20

17 Install retaining ring in housing (figures 19 and 20). After installing ring, pry around ring circumference with screwdriver to properly seat ring in groove.

19 Install 72,6 mm [2.86 in.] ID seal in housing (figure 22).

20 Install anti-cavitation valves and manual steering check valve (if used) in holes, as shown in figure 22.

21 Install spacer plate. Align bolt holes in spacer plate with tapped holes in housing.

25 mm [1 inch] Max.

Port Face

Drive

Pin Parallel with Port Face

Pin

Figure 21

18 Clamp housing in vise, as shown in Figure 21. Clamp lightly on edges of mounting area; do not overtighten jaws.

Note: Check to insure that spool and sleeve are flush or slightly below

14 hole surface of housing.

Attention: Clean upper surface of housing by wiping with palm of clean hand. Clean each of the flat surfaces of meter section parts in a similar way just before reassembly. Do not use cloth or paper to clean surfaces.

Figure 23

22 Rotate spool and sleeve assembly until pin is parallel with port face (figure 23). Install drive, making sure drive is engaged with pin.

To assure proper alignment, mark drive as shown in figure 25, reference B. When marking drive, note relationship of slotted end of drive to splined end of drive.

9

10

110, 230, and 450 Series Steering Control Units

Reassembly

Seal Groove this

Side -002 Unit.

See Note inside

Front Cover

(page 2)

Seal washers are not used with 6 point (E10) or hex head screws and -002 end cap (-002 end cap does not have a o-ring groove).

Seal End Cap

Cap Screw

Seal

23 Lubricate and install 72,6 mm [2.86 in.] ID seal in spacer plate or gerotor (meter), (ref.) see note page 2. The lubrication will hold seal in place.

Meter

(Gerotor)

Star Valley

Figure 24

A

Seal Groove this

Side -002 Unit.

See Note

Inside Front

Cover (page 2)

B

Drive Spacer

Actual

Displacement cm 3 /r

[in 3 /r]

45 [ 2.8]

60 [ 3.6]

75 [ 4.5]

95 [ 5.9]

120 [ 7.3]

145 [ 8.9]

160 [ 9.7]

185 [11.3]

230 [14.1]

295 [17.9]

370 [22.6]

460 [28.2]

590 [35.9]

740 [45.1]

Item No. 5

Spacer

Length mm [in.]

None

None

None

3,56 [ .140]

6,10 [ .240]

10,29 [ .405]

12,19 [ .480]

15,62 [ .615]

21,97 [ .865]

28,45 [1.120]

41,15 [1.620]

53,67 [2.113]

66,37 [2.613]

91,77 [3.613]

Drive (Marked)

O-ring Groove this

Side -002 Unit —

Old Spacer Plate has No O-ring

Groove

Pin

C

D

Figure 26

Port Face

Figure 25

24 Align star valleys (reference A) with marked drive (reference B).

Valleys must align with pin. Note parallel relationship of reference lines A, B, C, and D in figure 25. Align bolt holes without disengaging gerotor (Meter) from drive.

25 When used, install drive spacer in gerotor (meter), see chart figure 26.

26 Lubricate and install 72,6 mm [2.86 in.] ID seal in gerotor (meter) or end cap, current end cap does not have the o-ring groove (ref. – see note page 20).

27 Install end cap on gerotor, aligning holes.

110, 230, and 450 Series Steering Control Units

Resassembly

6 4

1

Char-Lynn ®

Eaton Corp. Hydraulics Div.

Eden Prairie, MN 55344

000-0000-000

00/00/00

000-0000-000

2

3 7

5

Figure 27

28 Install 7 dry cap screws (and seal washers if applicable – see figure 26) in end cap. Pretighten screws to 17 Nm [150 lb-in], then torque screws to 25-30 Nm [225-275 lb-in] in sequence shown in figure 27.

11

110, 230, and 450 Series Steering Control Units

How to Order Replacement Parts

Each Order Must Include the Following:

1. Product Number

2. Date Code

3. Part Name

4. Part Number

5. Quantity of Parts

For additional literature contact Eaton Corp. Hydraulics

Division 15151 Highway 5 Eden Prairie, MN 55344.

Specifications and performance data, Catalog No. 11-872

Replacement part numbers and kit information — Parts

Information No. 6-321

Char-Lynn

Product number

®

Eaton Corp. Hydraulics Div.

Eden Prairie, MN 55344

Product Number

000 0000 000

Product Line

Identification

Number

Product

Identification

Number

Date Code

00 00

Week of

Year 01

Thru 52

Last

Number(s) of Year

Engineering

Change

Code

Bar Code Label — Launch Date June, 1999

Customer part number or base unit number if it has a column or valve assembled

Month / Day / Year

Eaton Part Number

Char-Lynn ®

Eaton Corp. Hydraulics Div.

Eden Prairie, MN 55344

000-0000-000

00/00/00

000-0000-000

Port Face

Eaton

Fluid Power Group

Hydraulics Business USA

14615 Lone Oak Road

Eden Prairie, MN 55344

USA

Tel: 952-937-9800

Fax: 952-294-7722 www.eaton.com/hydraulics

© 2008 Eaton Corporation

All Rights Reserved

Printed in USA

Document No. C-STCU-TS010-E

Supersedes 07-309

December 2008

Eaton

Fluid Power Group

Hydraulics Business Europe

Route de la Longeraie 7

1110 Morges

Switzerland

Tel: +41 (0) 21 811 4600

Fax: +41 (0) 21 811 4601

Eaton

Fluid Power Group

Hydraulics Business Asia Pacific

11th Floor Hong Kong New World Tower

300 Huaihai Zhong Road

Shanghai 200021

China

Tel: 86-21-6387-9988

Fax: 86-21-6335-3912