Page 1
®
Char-Lynn
Power Steering
Repair Information
No. 7-309
August, 1999
110, 230 and 450 Series
Steering Control Units
001 002
Page 2
110, 230, and 450 Series Steering Control Units
Cast
End
Cap
1
O-ring Groove
2
3
O-ring Groove
4
7
3
5
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
Low Input Torque
Spring (4)/Spacer (2)
Package
Standard Input Torque
Spring (6)
Package
6
31
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.
23
9
3
30
12
11
11
11
22
9
10
See Note Below (lower right)
8
U
13
14
13
Previous Manual
Steering Check Valve
V
W
X
Y
17
15
18
19
16
Z
Ref.
Description
No.
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
Pin, Centering
10
2
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.
Description
No.
11 Spring, Centering
12 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.
Description
No.
23 Pin, Roll, 34,92 mm [1.375 in.] Length
30 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
W
Seat, Check Ball
X
Seal — 9,2 mm [.36 in.] ID
Y
Screw, Set
Z
Page 3
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
Page 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
25 mm
[1 inch]
Max.
-002 Steering
Control Unit
with 6 Point
(E10) Drive Screws
or Current Hex
Head Screws
Figure 1
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
Meter (Gerotor)
Seal
Inside Front
Cover (Page 2)
Spacer
Figure 3
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.
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)
Cap Screw
Seal
Figure 2
4
Drive
Spacer Plate
Seal
Figure 4
8 Remove drive.
9 Remove spacer plate.
10 Remove seal from housing.
11 Remove housing from vise.
O-ring Groove
this Side -002
Unit — Old
Spacer Plate
has No O-ring
Groove
Page 5
110, 230, and 450 Series Steering Control Units
Special Seal Gland Marked
with Groove for Identification
Replacement
Teflon Seal (1 Piece)
Springs (4)
Spring
Spacers (2)
Low Input
Torque
Steering
Control
Units
Old 3 Piece
Teflon Seal
Standard Seal
Gland Not Marked
with Groove (Special Seal
Gland Shown with Groove Above)
Quad Ring Seal
Springs (6)
Standard Input
Torque
Steering
Control
Units
Dust Seal
Dust Seal
Disassembly
Manual Steering Check
Valve (when applicable)
Early Units* Built
with these Parts
Retainer Plug
Spring
Anti-Cavitation Valves
*
for Cylinder Ports
Ball
Roll Pin
Ball
Ball
Roll Pin
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
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.
14 Lift spool and sleeve assembly up just far enough to free gland
bushing from housing (figure 7). Remove bushing.
Figure 6
Figure 7
Seal Gland Bushing
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
Low Input Torque Units:
15
seal from seal gland bushing.
quad ring seal from seal gland bushing.
16 Use thin bladed screwdriver to pry dust seal from seal gland
bushing. Do not damage bushing.
(see figure 8).
Remove back-up ring, o-ring and Teflon
Standard Input Torque Units:
Remove
5
Page 6
110, 230, and 450 Series Steering Control Units
Disassembly
Bearing Race
Low Input Torque
Spring/Spacer Package
Standard Input Torque
Seal
Needle Thrust Bearing
Figure 9
17 Remove two bearing races and needle thrust bearing and seal from
spool and sleeve assembly.
Figure 11
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 appli-
cable) by removing set screw with 1/4 in. hex key.
Pin
Warning: Pin may slide
outward from spool and
sleeve locking these
parts into housing, please
follow instructions.
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.
6
Manual Steering
Check Valve –
Early Design
Shown Here
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
Page 7
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.
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
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.
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.
Low Torque
Spring Spacers (2)
Standard Torque
Figure 15
7 Centering Springs for Low Input Torque Units:
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
Low input torque
7
Page 8
110, 230, and 450 Series Steering Control Units
Disassembly
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.
Pin
12 Place housing on clean lint free colth. Install 47,2 mm [1.86 in.] ID
seal in housing (figure 18).
Bearing Race
Seal
Needle Thrust Bearing
Figure 18
Figure 16
10 Insert pin through spool and sleeve assembly until pin is flush at
both sides of sleeve.
Figure 17
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.
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:
bushing. Smooth seal in place with finger. Do not use any seal that
falls freely into pocket of bushing.
Install quad ring seal in seal gland
Retaining Ring Large Socket
Dust Seal
Seal Gland
Bushing
(with seals)
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.
8
Page 9
110, 230, and 450 Series Steering Control Units
Pin
Drive
Pin Parallel
with Port Face
Port Face
Reassembly
Standard Torque Low Torque
Screwdriver
Dust Seal
Retaining
Ring
Seal Gland
Bushing
Quad Ring
Seal
Seal
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.
*
Teflon Seal
Bushing
with
Identification
Groove
Roll Pin (2)
40,00 mm
[1.575 in.] L
Ball (2)
4,762 mm
[.1875 in.] OD
Anti-Cavitation Valves
*
for Cylinder Ports
Early Units
with these Parts
Retainer Plug
Spring
Ball
*
Built
O-ring Groove this
Side -002 Unit —
Old Spacer Plate
has No O-ring
Groove
Manual Steering
Check Valve
(when applicable)
Roll Pin (1)
34,92 mm
Seal
[1.375 in.] L
Ball 6,35 mm
[.250 in.] OD
3 Piece
Seal
Cross Section of Old and New Seal
1 Piece
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.
25 mm [1 inch] Max.
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 22
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.
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
Page 10
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
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.
Seal Groove this
Side -002 Unit.
See Note
Inside Front
Cover (page 2)
Meter
(Gerotor)
Star Valley
A
B
Drive (Marked)
O-ring Groove this
Side -002 Unit —
Old Spacer Plate
has No O-ring
Groove
C
D
Drive Spacer
Seal
End Cap
Actual
Displacement
cm
[in
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]
Figure 26
Cap Screw
Item No. 5
3
/r
3
/r]
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]
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.
Page 11
110, 230, and 450 Series Steering Control Units
Resassembly
46
®
Eaton Corp. Hydraulics Div.
Char-Lynn
1
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
Page 12
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
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
4. Part Number
5. Quantity of Parts
Char-L ynn
Product number
®
Eaton Corp. Hydraulics Div.
Eden Prairie, MN 55344
Product Number
Week of
Year 01
Thru 52
000 0000 000
Product Line
Identification
Number
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
Product
Identification
Number
Engineering
Change
Code
®
Char-Lynn
000-0000-000
000-0000-000
Date Code
00 00
Last
Number(s)
of Year
Eaton Corp. Hydraulics Div.
Eden Prairie, MN 55344
00/00/00
Eaton Corporation
Hydraulics Division
15151 Hwy. 5
Eden Prairie, MN 55344
Telephone: 612/937-7254
Fax: 612/937-7130
Sumitomo Eaton
Hydraulic Company Ltd.
Ooi-Cho Kameoka-Shi
621-0017 Kyoto
Japan
Telephone: [+81] 771-22-9601
Fax: [+81] 771-29-2020
www.eatonhydraulics.com
Copyright Eaton Corporation, 1981, 1988, 1993, and 1999
All Rights Reserved
Form No. 7-309
Printed in USA
Eaton Ltd.
Hydraulics Division
Glenrothes, Fife
Scotland, KY7 4NW
Telephone: [+44] (0)1592-771-771
Fax: [+44] (0)1592-773-184
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 B.V.
Boeing Avenue 11
1119 PC Schiphol-Rijk
The Netherlands
Telephone: [+31] (0)20-655 6776
Fax: [+31] (0)20-655 6800
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
Sumitomo Eaton Hydraulic Co.
8 Temasek Blvd.
42-01 Suntec Tower Three
Singapore 03988
Telephone: [+65] 832-7727
Fax: [+65] 832-7733
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
Port Face
ACCREDITED BY
THE DUTCH COUNCIL
FOR CERTIFICATION
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.
Reg. No. 24
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