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]