Eaton Char-Lynn VersaSteer 10 Series Owner's manual

Series 10 VersaSteer™
Parts and Repair Information

2EATON Hydraulics Series 10 VersaSteer Parts and Repair October 2004
Introduction
ID Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Parts
Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Gerotor parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-16
Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-12
Series 10
VersaSteer
Table of Contents
This manual provides service
information for Char-Lynn®
Series 10 VersaSteer™
Steering Control Units. Step
by step instructions for
complete disassembly,
inspection and
reassembly of the control
unit are given.
The following
recommendations should be
followed to insure
successful repairs.
•Most repairs require the
removal of the control
unit from the vehicle.
•Cleanliness is extremely
important.
•Clean the port areas
thoroughly before
disconnecting the
hydraulic lines.
•Plug the control unit
ports and cover open
hydraulic lines
immediately after they
have been
disconnected.
•Drain the oil and clean
the exterior of the
control unit before
making repairs.
•Wash all metal parts in
clean solvent.
•Use filtered, moisture-
free compressed air to
dry the parts.
Do not wipe them dry
with paper towels or
cloth – lint in a hydraulic
system will cause
damage.
•Always use new seals
when reassembling
hydraulic control units.
•Lubricate new rubber
seals with a petroleum
jelly before installation.
•Torque all bolts over
gasketed joints, then
repeat the torquing
sequence to make up for
gasket compression.
After all repairs are
complete it is essential to
verify the accuracy of control
unit repairs on an
authorized test stand.
Introduction

ID Tag
Ordering Parts
Tools
Port Face
Eaton Corp. Hydraulics Div.
Eden Prairie, MN 55344
Customer part number
or base unit number if it
has a column or valve
assembled
Bar Code Label — Launch Date June, 1999
Month / Day / Year
Eaton Part Number
Each order must include the following:
1. Product Number
2. Date Code
3. Part Name
4. Part Number
5. Quantity of Parts
Refer to specific part listings
for your Char-Lynn®VersaSteer™
Steering Control Unit when ordering
replacement parts. Listings
are available from Eaton.
Sample tag shows identification.
When ordering replacement
parts, you must include the
following information:
For additional literature contact
Eaton Hydraulics at
14615 Lone Oak Road,
Eden Prairie, MN 55344
http://hydraulics.eaton.com
Tools Required For Disassembly and Assembly
• Screwdriver (102-152 mm [4 in. - 6 in.] long, x 3 mm [118 in.]
thin flat blade).
• 1/2 inch socket for current hex head cap screws.
• Breaker bar wrench.
• Torque wrench (30 Nm [300 lb-in] capacity).
• 11/16 inch wrench.
Special Tools:
• Plunger and Sleeve Tool No. 600792-001*
*Tools available—by special order—through our service department.
How to Order
Replacement Parts
3EATON Hydraulics Series 10 VersaSteer Parts and Repair October 2004

4EATON Hydraulics Series 10 VersaSteer Parts and Repair October 2004
Parts
Assembly
Drawing
2
21
21
22
22
22
23
23
24
25
49
48
3
55
3
6
1
3
7
13
14
13
18
19
22
21
12
9
8a
8b
or
Hex Head Screw
85
89
53
88
86
86a
86
86a
10, 11
3
5
3
52
3
56
or
Low
Medium
Standard
16
15
60
Manual Steering
Check Valve
or
or
*
*Anti-cavitation valve parts will vary
according to configuration.

Parts
Table 1.0 Parts
List
Series 10
VersaSteer
ITEM REFERENCE
NO. PART NO. QTY. DESCRIPTION PAGE
1 See Table 1.0 7 Cap Screw, Hex Head 6
2 23901-000 1 Cap, End
3 5776-000 6 Seal, 72,6 mm [2.86 in.] ID
5 113094-000 1 Plate, Spacer
6 4998212-001 1 Drive
7 204107-XXX 1 Housing, Valve
8a 1 Control Sleeve
8b 1 Control Spool
915-000 1 Pin, Centering
10 112714-000 2 or 3 Spring, Spacer
11 113599-000 4 or 6 Spring, Centering
12 112737-000 1 Retainer Spring
13 14880-000 2 Bearing Race
14 5544-000 1 Bearing, Needle Thrust
15 9332-000 1 Seal – 24,9 mm [.98 in.] ID
16 844-000 1 Dust Seal
18 16026-422P 1 Pin, Roll– 34,92 mm [1.375 in.] Length
19 285020-080 1 Ball – 6,35 mm [.25 in.] OD
21 16026-436 2 Pin, Roll – 40,00 mm [1.575 in.] Length
22 18015-000 2 Ball, Check – 6,35 mm [.250 in.] OD
23 230400-000 2 Compression Spring
or 4999516-000 2 Compression Spring (See main parts assembly drawing)
24 113598-000 2 Anti-cav plug retainer
25 230313-000 2 Compression Spring
48 202038-000 1 Ring, Seal
49 16101-322 1 Ring, Back-up
52 4999016-001 1 Plate, Valve
53 4999092-001 1 Valve S/A
55 4999015-000 1 Plate Valve
56 See Table 1.0 1 Gerotor Sub-assembly 6
60 4999651-001 1 O-ring
85 230397-000 1 Spring, Compression
86 112114-010 2 Fitting
86a 250003-906 2 O-Ring
88 4998914-001 1 Piston
89 4992809-001 1 Piston, Guide Spring
5EATON Hydraulics Series 10 VersaSteer Parts and Repair October 2004

1. Clamp unit in vise,
meter end up. Clamp
lightly on edges of port
face sides (see figure1).
Use protective material
on vise jaws. Housing
distortion could result if
jaws are overtightened.
25 mm
[1 inch]
Max.
Gerotor (Meter) End
Cleanliness is extremely
important when repairing a
steering control unit. Work
in a clean area. Before dis-
connecting lines, clean port
area of unit thoroughly. Use
a wire brush to remove
foreign material and debris
from around exterior joints
of the unit.
We recommend that you
keep the unit in a vise during
disassembly. Follow the
clamping procedures
explained throughout the
manual.
Figure 1
6EATON Hydraulics Series 10 VersaSteer Parts and Repair October 2004
Parts
Gerotor
Table 1.0
ACTUAL
DISPL. REF. NO. 4 REF. NO. 29
cm3/r GEROTOR CAP SCREW
[in3/r] PART NO. Width mm[in] PART NO. LENGTH mm[in]
60 [3.6] 201234-023 10,2 [.40] 16336-530 76,2 [3.00]
75 [4.5] 201234-024 10,2 [.40] 16336-530 76,2 [3.00]
95 [5.9] 201234-003 13,2 [.52] 16336-531 79,5 [3.13]
120 [7.3] 201234-009 16,5 [.65] 16336-532 82,6 [3.25]
145 [8.9] 201234-020 20,1 [.79] 16336-533 85,9 [3.38]
160 [9.7] 201234-004 21,9 [.86] 16336-534 88,9 [3.50]
185 [11.3] 201234-005 25,4 [1.00] 16336-534 88,9 [3.50]
230 [14.1] 201234-031 31,7 [1.25] 16336-537 98,6 [3.88]
295 [17.9] 201234-035 40,4 [1.59] 16336-541 104,9 [4.13]
370 [22.6] 201234-008 50,8 [2.00] 16336-545 117,6 [4.63]
460 [28.2] 201234-033 63,5 [2.50] 16336-551 133,4 [5.25]
590 [35.9] 201234-036 80,8 [3.18] 16336-556 146,1 [5.75]
740 [45.1] 8618-034 101,6[4.00] 16336-564 165,1 [6.50]
Disassembly

Disassembly
2. Remove 5/16 in. cap
screws.
3. Remove end cap.
4. Remove seal.
Note: All Series 10
VersaSteer™ steering
control units have a low
slip sealed gerotor
star, this unit inculdes a
ring seal and a back-up
ring.
Figure 2
7EATON Hydraulics Series 10 VersaSteer Parts and Repair October 2004
5. Remove gerotor (meter).
Be careful not to drop star.
6. Remove seal from
valve plate.
7. Remove valve plate.
8. Remove seal from
valve S/A.
Seal
Seal
Valve Plate
Valve S/A
Gerotor
(Meter)
Figure 3
Screw, Cap, Hex Head
Cap, End
Seal
Seal, Ring
Low Slip
Sealed
Gerotor
Star Only
Ring, Back-up
Gerotor

8EATON Hydraulics Series 10 VersaSteer Parts and Repair October 2004
Disassembly
Valve S/A
Seal
Seal
Valve Plate
Drive
9. Remove valve Sub-
assembly
10. Remove seal from
valve plate.
11. Remove valve plate
Seal
Seal
Drive
Plate, Spacer
Drive, Spool, and Sleeve
Housing
12. Remove seal from spacer
plate.
13. Remove spacer plate.
14. Remove seal from housing.
15. Pull drive and twist to
remove SP/SL drive
assembly from housing.
16. Remove housing from vise.
Figure 5
Attention: Do not bind
spool and sleeve in housing.
Rotate spool and sleeve
assembly slowly when
removing it from housing.
17. Carefully remove bearing
and races, anti-cavitation
valves and manual
steering check valve
(roll pin and ball) from bolt
holes by tipping housing
Gerotor side down.
(see figure 6).
Figure 4

9EATON Hydraulics Series 10 VersaSteer Parts and Repair October 2004
Disassembly
19. Carefully Remove Seal with
a thin-blade screw driver.
Do not scratch seal groove
with screw driver.
20. Use thin bladed screw
driver to pry dust seal
from housing. Do not
damage housing.
Ball
Race
Bearing
Race
Ball
Roll Pin
Roll Pin
O-ring
Seal
Dust Seal
*
Anti-Cavitation Valves
for Cylinder Ports
Reference Page 4
for other configurations
Manual Steering
Check Valve
Figure 6
18. 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.
21. Push pin from spool and
sleeve assembly.
22. Remove Drive
23. Push spool partially from
control end of sleeve,
then carefully remove
centering springs and
retaining ring from spool
by hand (figure 7).
*Note
Standard input torque unit
uses six centering springs
and two spacers.
Medium input torque unit
uses four centering
springs and three spacers.
Low input torque unit
uses four centering
springs and two spacers.
Standard Input Torque
Spring/Spacer Package
Low Input Torque
Spring/Spacer Packag
e
Medium Input Torque
Spring/Spacer Package
Figure 7

Assembly
1. Reassemble valve parts
with new o-rings on
plugs (See figure 9).
Piston
Valve S/A
O-ring
O-ring
Piston, Guide Spring
Spring, Compression
Fitting
Fitting
Figure 9
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. 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.
Assembly Cleanliness
Recommendations
10 EATON Hydraulics Series 10 VersaSteer Parts and Repair October 2004
Disassembly
24. Disassemble valve sub-assembly as
shown in figure 8.
Piston
Valve S/A
O-ring
O-ring
Piston, Guide Spring
Spring, Compression
Fitting
Fitting
Figure 8
1/4” Hex Key
*Note: The fittings included in the
valve assembly are critical in
the operation of the valve,
and must not be switched
with another style.
Torque Fittings to
31-45Nm [23-33 lb-ft]

11EATON Hydraulics Series 10 VersaSteer Parts and Repair October 2004
2-Piece Shaft Seal
Installation
For installation of
o-ring: 4999651-001
and
Seal 9332-000
1. Place housing on a flat
work area as shown in
figure 11.
2. Lubricate seal and o-ring
with hydraulic oil before
installation
3. Align sleeve with
housing bore (figure 11)
4. Insert sleeve into
housing bore (Figure 12)
5. Place o-ring on plunger
(Figure 13).
Figure 10
Figure 11 Tool No. 600792-001
Assembly
2. Place housing on a flat
work area on a clean lint
free cloth.
Install press-fit
24,9 mm[.98 in.] ID seal
in housing with metal
suface of seal facing
toward housing (figure 10).
Figure 12 Figure 13

8. Align plunger with
sleeve (figure 16).
9. Push plunger into sleeve
until it bottoms out,
rotate 1/4 turn
(figure 17).
10. While holding sleeve in
housing, withdraw
plunger.
11. Withdraw sleeve.
12 EATON Hydraulics Series 10 VersaSteer Parts and Repair October 2004
7. Push seal onto plunger.
Lip of seal should be
between o-ring and
plunger. No gap should
exist between o-ring
and seal (figure 15).
Figure 15
Figure 16
Figure 17
Figure 18
Assembly
2-Piece Shaft Seal
Installation
6. Align seal with plunger.
cross section "L" shape
of seal should be upside
down (figure 14).
Figure 14
25mm[1in]
Bearing Race
Needle Thrust Bearing
Figure 19
Figure 20
13. Clamp housing in vice
(figure 19).
14. Install two bearing races
and thrust bearing as
shown in figure 20.
12. Inspect seal
installation. Seal
and o-ring must
both be within
shaft seal counter
bore of housing
(figure 18).

13EATON Hydraulics Series 10 VersaSteer Parts and Repair October 2004
Assembly
15. Assemble spool and
sleeve carefully so that
spring slots line up at the
same end. Rotate spool
while sliding parts
together. Test for free
rotation. Spool should
rotate smoothly in sleeve
with fingertip force
applied at splined end.
Align spring slots and
identification marks
(Figure 21) in spool and
sleeve and stand parts on
end of bench.
Identification Marks
Control Spool
Spring Slot
Control Sleeve
Figure 21
4
2
68
97
53
Standard
Torque
Medium
Torque
2468753
1
Spring Spacer
Spring Spacer
Springs
Low
Torque
246753
Figure 22
16. Installation of spring
spacers and springs, hold
spring retainer at an angle
as shown (see figure 22
reference number 1),
insert spring spacers and
springs one at a time in
sequence noted by
reference numbers 2 - 9
(standard torque), 2 - 8
(medium torque), 2- 7 (low
torque), then position
spring retainer correctly
over all these parts.
Adjust alignment of
spring parts with a
small screwdriver.

Figure 25
*Anti-Cavitation Valves
for Cylinder Ports
See page 4 for other
configurations
Ball 6,35 mm
[.250 in.] OD
Ball (2)
4,762 mm
[.1875 in.] OD Roll Pin (1)
34,92 mm
[1.375 in.] L
Roll Pin (2)
40,00 mm
[1.575 in.] L
Manual Steering
Check Valve
O-ring
Figure 24
14 EATON Hydraulics Series 10 VersaSteer Parts and Repair October 2004
17. Assemble drive and
spool/sleeve.
18. Insert pin through spool
and sleeve assembly
through hole in drive,
until pin is flush at both
sides of sleeve.
Pin
Figure 23
Assembly
19. Position spool and sleeve
assembly so that splined
end of spool enters 14
hole end of housing first
(figure 23).
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. Bring spool assembly
entirely within housing bore
until parts are flush at 14 hole
end of housing. With spool
assembly in this flush
position, check for free
rotation within housing by
turning assembly with
fingertip force at splined end.
20. Install 72,6 mm [2.86 in.]
ID O-ring in housing
(figure 25).
21. Install anti-cavitation
valves and manual
steering check valve (if
used) in holes, as shown
in figure 25. After
installing balls, inspect
holes to make sure they
are properly seated.
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 sec-
tion parts in a similar way just
before reassembly. Do not use
cloth or paper to clean surfaces.

Assembly
15EATON Hydraulics Series 10 VersaSteer Parts and Repair October 2004
Timing Reference Data —
Align star valley (reference A) with
marked drive (reference B). Valley
must align with pin. Note parallel
relationship of reference lines A, B,
C, and D in figure 27. Align bolt
holes without disengaging gerotor
(meter) from drive.
Figure 26
22. Install spacer plate.
Align bolt holes in spacer
plate with tapped holes
in housing.
23. Lubricate and install 72,6
mm [2.86 in.] ID seal in
spacer plate.
24. Install valve plate.
25. Lubricate and install 72,6
mm [2.86 in.] ID seal in
valve plate.
26. Install valve S/A,
see figure 26 for correct
position.
27. Lubricate and install 72,6
mm [2.86 in.] ID seal in
valve S/A.
28. Install valve plate.
29. Lubricate and install 72,6
mm [2.86 in.] ID seal in
valve plate.
30. Install gerotor, seal
groove up; note position
of star valleys in relation
to marked drive.
Valve S/A
Seal
Seal
Alignment
Reference —
Bolt Hole
on Center
(Port Face
Side)
Valve Plate
Spacer Plate
Valve Plate
Seal
Seal
Housing
Figure 27
Gerotor
Seal
Seal
Drive
(Marked)
Valve Plate
Meter
(Gerotor
Star Valley
Pin
Valve S/A
B
A
C

© 2005 Eaton Corporation
All Rights Reserved
Printed in USA
Document No. C-STCU-TS006-E
June 2005
Eaton
14615 Lone Oak Road
Eden Prairie, MN 55344
USA
Tel: [phone]
Fax: [phone]
www.hydraulics.eaton.com
Eaton
Dr.-Reckeweg-Str. 1
D-76532 Baden-Baden
Germany
Tel: [phone]
Fax: [phone]
Eaton
20 Rosamond Road
Footscray
Victoria 3011
Australia
Tel: [phone]
Fax: [phone]
34. Install 7 dry cap screws in
end cap. Pretighten cap
screws to 17Nm [150 lb-in],
then torque screws to
28-34 Nm [250-300 lb-in] in
sequence shown in
figure 29.
1
3
5
7
2
46
Figure 29
Assembly
Figure 28
31 Install back-up ring and seal
ring in gerotor star.
32. Lubricate and install 72,6 mm
[2.86 in.] ID seal in gerotor
(meter).
33. Install end cap on gerotor,
aligning holes.
Screw, Cap, Hex Head
Cap, End
Seal
Seal, Ring (metal)
Low Slip
Sealed
Gerotor
Star Ring, Back-up (rubber)
Gerotor
Groove cross section
w/ rings