Char-Lynn ® No. 7-309 August, 1999 Power Steering Repair Information 110, 230 and 450 Series Steering Control Units 001 002 110, 230, and 450 Series Steering Control Units 1 2 Low Input Torque Spring (4)/Spacer (2) Package O-ring Groove 3 12 Previous Manual Steering Check Valve U V W X Y Z O-ring Groove 4 Standard Input Torque Spring (6) Package 7 3 11 11 11 6 23 9 22 3 9 5 8 13 14 13 17 15 18 31 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. Cast End Cap 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. 1 2 3 4 5 6 7 8 9 10 2 Description Cap Screw, Hex Head Cap, End Seal, 72,6 mm [2.86 in.] ID Gerotor Spacer Plate, Spacer Drive Housing Sleeve, Control/Spool, Control Pin, Centering Ref. No. 11 12 13 14 15 16 17 18 19 22 Description Spring, Centering Spring, Spacer Bearing Race Bearing, Needle Thrust Seal, 47,2 mm [1.86 in.] ID Seal, 24,9 mm [.98 in.] ID Seal, Quad Ring, 26,7 mm [1.05 in.] ID Bushing, Seal Gland Ring, Retaining Ball, 6,35 mm [.250 in.] OD Ref. No. 23 30 31 U V W X Y Z Description Pin, Roll, 34,92 mm [1.375 in.] Length Ball, Check Pin, Roll, 40,00 mm [1.575 in.] Length * Retainer, Check Ball Ball, Check Seal — 7,6 mm [.30 in.] ID Seat, Check Ball Seal — 9,2 mm [.36 in.] ID Screw, Set 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. 3 110, 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. 2 Remove 5/6 in. cap screws and sealing washers, if used. 3 Remove end cap. 4 Remove seal. Seal Groove this Side -002 Unit. See Note Inside Front Cover (Page 2) 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. Meter (Gerotor) Gerotor (Meter) End Seal 25 mm [1 inch] Max. -002 Steering Control Unit with 6 Point (E10) Drive Screws or Current Hex Head Screws Spacer Figure 3 5 Remove meter. Be careful not to drop star. 6 Remove seal. 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) 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. O-ring Groove this Side -002 Unit — Old Spacer Plate has No O-ring Groove Drive Spacer Plate Cap Screw Seal Seal Figure 4 8 Remove drive. 9 Remove spacer plate. 10 Remove seal from housing. Figure 2 4 11 Remove housing from vise. 110, 230, and 450 Series Steering Control Units Disassembly Low Input Torque Steering Control Units Ball Manual Steering Check Valve (when applicable) Roll Pin Dust Seal Spring Spacers (2) Early Units* Built with these Parts Ball Spring Retainer Plug Ball Roll Pin Springs (4) Replacement Teflon Seal (1 Piece) * Anti-Cavitation Valves for Cylinder Ports Old 3 Piece Teflon Seal 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). Special Seal Gland Marked with Groove for Identification Standard Input Torque Steering Control Units Control End Dust Seal Springs (6) Quad Ring 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 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. Figure 7 14 Lift spool and sleeve assembly up just far enough to free gland bushing from housing (figure 7). Remove 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 Low Input Torque Spring/Spacer Package Standard Input Torque Bearing Race Needle Thrust Bearing Seal Figure 9 Figure 11 17 Remove two bearing races and needle thrust bearing and seal from spool and sleeve assembly. 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. Pin 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. O-ring 7,7 mm [.30 in.] ID Figure 10 Check Ball Check Ball Seat Set Screw 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. 6 Check Ball Retainer 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. Spring Slot 24 Remove two seals from check valve seat. Assemble Input Shaft End First 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. Input Shaft End Control Spool 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. 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. Control Sleeve Identification Marks Figure 14 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 Low Torque Spring Spacers (2) Set Screw Check Ball Seat O-ring 9,3 mm [.36 in.] ID Check Ball Check Ball Retainer O-ring 7,7 mm [.30 in.] ID Standard Torque 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 Needle Thrust Bearing Seal Pin Figure 18 Figure 16 10 Insert pin through spool and sleeve assembly until pin is flush at both sides of sleeve. 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 Large Socket Dust Seal Figure 17 Seal Gland Bushing (with seals) 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. 8 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 Roll Pin (2) 40,00 mm [1.575 in.] L Low Torque* Standard Torque Spring Retainer Plug Teflon Seal Screwdriver Early Units* Built with these Parts Dust Seal Ball Retaining Ring O-ring Groove this Side -002 Unit — Old Spacer Plate has No O-ring Groove Manual Steering Check Valve (when applicable) Seal Gland Bushing Quad Ring Seal Ball (2) 4,762 mm [.1875 in.] OD Seal Roll Pin (1) 34,92 mm [1.375 in.] L Seal Ball 6,35 mm [.250 in.] OD Bushing * Anti-Cavitation Valves with Identification for Cylinder Ports Groove * 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 19 Install 72,6 mm [2.86 in.] ID seal in housing (figure 22). Cross Section of Old and New Seal Figure 20 20 Install anti-cavitation valves and manual steering check valve (if used) in holes, as shown in figure 22. 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. 21 Install spacer plate. Align bolt holes in spacer plate with tapped holes in housing. Port Face 25 mm [1 inch] Max. Drive Pin Parallel with Port Face Pin Figure 21 Figure 23 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. 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. 9 110, 230, and 450 Series Steering Control Units Reassembly 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 Groove this Side -002 Unit. See Note inside Front Cover (page 2) Seal End Cap Cap Screw Seal Figure 24 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. Drive Spacer A Meter (Gerotor) Star Valley Seal Groove this Side -002 Unit. See Note Inside Front Cover (page 2) B Drive (Marked) Actual Displacement cm3/r [in3/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] C Figure 26 O-ring Groove this Side -002 Unit — Old Spacer Plate has No O-ring Groove D Pin 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. 10 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 Char-Lynn® 1 Eaton Corp. Hydraulics Div. Eden Prairie, MN 55344 2 000-0000-000 00/00/00 000-0000-000 7 3 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 Date Code Char-Lynn ® 00 00 Product number Each Order Must Include the Following: 1. Product Number 2. Date Code 3. Part Name 4. Part Number 5. Quantity of Parts Eaton Corp. Hydraulics Div. Eden Prairie, MN 55344 Product Number Week of Year 01 Thru 52 Last Number(s) of Year 000 0000 000 For additional literature contact Eaton Corp. Hydraulics Division 15151 Highway 5 Eden Prairie, MN 55344. Specifications and performance data, Catalog No. 11-872 Product Line Identification Number Product Identification Number Engineering Change Code Replacement part numbers and kit information — Parts Information No. 6-321 Bar Code Label — Launch Date June, 1999 Customer part number or base unit number if it has a column or valve assembled Char-Lynn® Eaton Corp. Hydraulics Div. Eden Prairie, MN 55344 000-0000-000 Month / Day / Year 00/00/00 000-0000-000 Eaton Part Number Port Face Eaton Corporation Hydraulics Division 15151 Hwy. 5 Eden Prairie, MN 55344 Telephone: 612/937-7254 Fax: 612/937-7130 Eaton Ltd. Hydraulics Division Glenrothes, Fife Scotland, KY7 4NW Telephone: [+44] (0)1592-771-771 Fax: [+44] (0)1592-773-184 Eaton B.V. Boeing Avenue 11 1119 PC Schiphol-Rijk The Netherlands Telephone: [+31] (0)20-655 6776 Fax: [+31] (0)20-655 6800 Sumitomo Eaton Hydraulic Co. 8 Temasek Blvd. 42-01 Suntec Tower Three Singapore 03988 Telephone: [+65] 832-7727 Fax: [+65] 832-7733 Sumitomo Eaton Hydraulic Company Ltd. Ooi-Cho Kameoka-Shi 621-0017 Kyoto Japan Telephone: [+81] 771-22-9601 Fax: [+81] 771-29-2020 Eaton Ltd. 7th Floor, Woo Duk Building 832-2 Yeoksam-Dong, Kangnam-Ku Soeul 135-750 Korea Telephone: [+82] 2-557-0595 Fax: [+82] 2-557-1634 Eaton Hydraulics (Shanghai) Co. Ltd. 388 Aidu Road, Waigaogiao FTZ Pudong New Area Shanghai 200137 Peoples Republic of China Telephone: [+86] 21-5046 0758 Fax: [+86] 21-5046 0767 Jining Eaton Hydraulic Co. Ltd. 6 Ji Da Road Jining City Shandong Province 272131 Peoples Republic of China Telephone: [+86] 537-2221288 Fax: [+86] 537-2221557 www.eatonhydraulics.com Form No. 7-309 Copyright Eaton Corporation, 1981, 1988, 1993, and 1999 All Rights Reserved Printed in USA ACCREDITED BY THE DUTCH COUNCIL FOR CERTIFICATION Reg. No. 24 ISO-9001 CERTIFICATED FIRM DET NORSKE VERITAS INDUSTRY BV, THE NETHERLANDS Qualitiy System Certified Products in this catalog are manufactured in an ISO-9001-certified site.