Eaton Char-Lynn User manual

T E
LR
P
Power Steering
Steering Control Unit (SCU)
Parts and Repair Information
Square Housing
with Side Ports
Round Housing
with Side Ports
Round Housing
with End Ports
5 Series
Steering
Control Units
001

2 EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006
Series 5
Steering
Control Unit
Table of Contents
Introduction
This manual provides service
information for Char-Lynn®
Series 5 Steering Control Units.
Step by step instructions for
complete disassembly, inspec-
tion and reassembly of the con-
trol 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 thor-
oughly 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, moisturefree
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 accura-
cy of control unit repairs on an
authorized test stand.
Introduction ......................................................................................................................................................................................................2
General Information
Ordering Parts..........................................................................................................................................................................................3
Tools ........................................................................................................................................................................................................3
Round and Square Housing with Side Ports
Exploded View..........................................................................................................................................................................................4
Parts List ..................................................................................................................................................................................................5
Disassembly ............................................................................................................................................................................................6
Reassembly..............................................................................................................................................................................................7
Round Housing with End Ports
Exploded View..........................................................................................................................................................................................8
Parts List ..................................................................................................................................................................................................9
Disassembly ..........................................................................................................................................................................................10
Reassembly............................................................................................................................................................................................11
2-Piece Shaft Seal Assembly..........................................................................................................................................................................12

3EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006
General
Information
Ordering Parts
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
Refer to specific part listings
for your Char-Lynn® Steering
Control Unit when ordering
replacement parts. Listings are
available from Eaton. Sample
tag shows identification.
For additional literature contact
Eaton Hydraulics at:
14615 Lone Oak Road
Eden Prairie, MN 55344
http://hydraulics.eaton.com
Tools Required:
• 10 mm Socket (13 mm Socket
for End-Ported Units)
• 7/8 in. Socket
•Torque Wrench
(31 Nm [275 lb-in] Capacity)
• Small Blade Screwdriver
SpecialTools:
• Plunger and SleeveTool (two-
piece seal) No. 600801-001*
* Tools available—by special order—
through our service department.
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

4 EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006
Dust
Seal
Housing Quad
Seal**
Thrust
Bearing
Sleeve
Spool
Pin
Standard Torque
Centering Springs*
Bearing
Race (2)
O-ring
Seal**
O-ring
Seal**
Wear
Plate
Drive
Gerotor
Manual Steering
Relief Valve
O-ring**
O-ring**
O-ring**
O-ring** Seal
Ring**
End
Cap
Cap
Screw
(7)
Plug
Plug
Check
Ball
Spring
Retaining
Ring*
Low Torque
Centering Springs*
Round and
Square Housing
with Side Ports
ExplodedView
*Round housing shown,
but applies to square
housing also.

5EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006
Round and
Square Housing
with Side Ports
Parts List
ITEM NO. PART NO. QTY. DESCRIPTION REFERENCE PAGE
1 See Table 2.0 7 Cap Screw, Hex Head 6
2 22994-000 1 Cap, End
4 See Table 2.0 1 Gerotor, Sub-assembly 6
5 22993-000 1 WearPlate
6 4994693-001 1 Drive
9 22853-000 1 Drive Pin
13 4997396-001 2 Bearing Race
14 4996933-001 1 Bearing, Needle Thrust
16 4997708-001 1 Dust Seal
REPLACEMENT PART NO. DESCRIPTION
64456-00 Centering Spring Kit - Standard Torque (contains parts with *)
990170-000 Centering Spring Kit - Low Torque (contains parts with **)
990252-000 Seal Kit - Standard Back Pressure (contains parts with **)
9900256-000 Seal Kit - High Back Pressure (contains parts with **)
9900321-000 Seal Kit - Viton, PM Gerotor(contains parts with **)
9900323-000 Seal Kit - Viton, Steel Gerotor(contains parts with **)
Table 1.0
Round and Square
Housing with Side Ports
ACTUAL DISPLAY REFERENCE NO. 4 GEROTOR REFERENCE NO. 29 CAP SCREW
cm3/r[in3/r]Part No. Width mm [in]Part No. Length mm [in]
31.5 [1.92] 4996815-001 7.45 [.290] 14543-003 35 [1.38]
39.5 [2.41] 4996815-002 9.3 [.366] 14543-003 35 [1.38]
50.8 [3.10] 4996815-003 8.3 [.326] 14543-003 35 [1.38]
63.1 [3.85] 4996815-004 10.2 [.400] 14543-003 35 [1.38]
73.8 [4.50] 4996815-005 12.1 [.476] 14543-002 40 [1.57]
100 [6.10] 4996815-006 16.3 [.642] 14543-004 45 [1.77]
120 [7.33] 4996815-007 19.5 [.768] 14543-004 45 [1.77]
Table 2.0
Gerotor

6 EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006
O-ring
Seal
O-ring
Seal
Wear
Plate Drive
Gerotor
Seal
Ring
Manual Steering
Check/Relief Valve
O-ring
O-ring O-ring
End
Cap
Cap
Screw
(7)
Plug
Dust
Seal
Housing
Bearing Race (2)
Spool and Sleeve
Quad
Seal**
Thrust
Bearing
Round and
Square Housing
with Side Ports -
Disassembly
Disassembly
Cleanliness is extremely impor-
tant when repairing hydraulic
Steering Control Units (SCU).
Work in a clean area. Before
disconnecting the hydraulic
lines, clean the port area of the
SCU. Before disassembly, drain
the oil, then plug the ports and
thoroughly clean the exterior of
the SCU. During repairs, always
protect machined surfaces.
1. Remove the seven cap
screws and disassemble the
SCU as shown in
figure 1.
2. Remove the plug and
manual steering check
as shown in figure 1.
Note:The manual steering
check may be a check ball or
a check/relief valve.
3. Slide the spool and sleeve
from the housing, see
figure 2.
4. Remove the thrust bearing
and bearing races.
5. Remove the quad seal.
Disassembly
6. Using a small blade screw-
driver, carefully pry the
dust seal from the housing.
Important: Do not damage
the dust seal seat.
7. Remove the pin that holds
the spool and sleeve togeth-
er, see figure 3.
8. Carefully slide the spool out
of the sleeve.The springs
and retaining ring will stay
with the spool as it’s
removed.
9. Remove the retaining ring
and springs.
Caution:The centering
springs are under tension;
remove the retaining ring
carefully.
Figure 1
Figure 2
Port Face
Eaton Corp. Hydraulics Div.
Eden Prairie, MN 55344
13
14
A-273-008
SECTION
LOW TORQUE
D-D
12
Anti-CavitationValves
(located under these two cap screws)
Low Torque

7EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006
Reassembly
Check all mating surfaces.
Replace any parts with scratch-
es or burrs that could cause
leakage. Wash all metal parts in
clean solvent. Blow them dry
with pressurized air. Do not
wipe parts dry with paper tow-
els or cloth as lint in a hydraulic
system will cause damage.
Note: Always use new
seals when reassembling
hydraulic steering control units.
Refer to page 5 for seal kit
part numbers.
Important: During reassembly
lubricate the new seals with
a petroleum jelly such as
Vaseline®. Also lubricate
machined surfaces and bearings
with clean hydraulic fluid.
10. Install the quad seal
(see page 12 for 2-piece
seal installations):
• Put one of the bearing
races and sleeve into
the housing.
•Together, the housing and
bearing race create a groove
into which the
quad seal will be installed.
• Hold the bearing race tightly
against the input end of the
housing by pushing on the
gerotor end of the sleeve.
• Fit the quad seal into its seat
through the input end of the
housing. Be sure
the seal is not twisted.
• Remove the sleeve and
bearing race.
11. Lubricate and install the dust
seal (see Figure 4 for correct
seal orientation).
12. Install the centering springs
in the spool. It is best to
install the two flat pieces
first. Next, install the curved
pieces, three
at a time.
13. Fit the retaining ring over
the centering springs.
14. Apply a light coating of
clean hydraulic fluid to
the spool and slide it into
the sleeve. Be sure the cen-
tering springs fit into the
notches in the sleeve.
15. Install the drive, be sure the
slot in the drive engages
the pin.
16. Install the pin
(see Figure 3).
17. Apply a light coating of
petroleum jelly to the
inner edge of the dust
and quad seals.
18. Put the thrust bearing and
races into the housing.
The thrust bearing goes
between the two races
(see Figure 2).
19. Apply a light coating of
clean hydraulic fluid to
the spool and sleeve assem-
bly and slide it
into the housing.
Important: Do not damage
the dust or quad seals..
20. Clamp the housing in a vise
as shown in Figure 5. Use
just enough clamping force
to hold the housing secure-
ly.
21. Lubricate and install a new
o-ring seal in the groove in
the housing.
22. Install the wear plate and
align the holes in the wear
plate with threaded holes in
the housing.
Note:The holes in
the wear plate are
symmetrical.
23. Lubricate and install a new
o-ring seal in the groove in
the wear plate.
24. Install the gerotor and align
the screw holes.
25. Lubricate and install a new
o-ring seal in the groove in
the gerotor ring.
26. Lubricate and install a new
o-ring and seal ring in the
groove in the gerotor star.
27. Install end cap and seven
cap screws.Tighten cap
screws, in a crisscross pat-
tern, to 16 -18 Nm
[140 -160 lb-in].
28. Remove the SCU from
the vise.
29. Install the relief valve/check
or check ball and plug. Use
a new o-ring and tighten the
plug to 17 Nm [150 lb-in].
Quad Seal
Dust Seal Thrust Bearing
and Race (2)
Round and
Square Housing
with Side Ports -
Reassembly
Figure 4
Figure 5
Standard Torque
Centering Springs
and Spacers
Sleeve
Pin
Spool
Spring
Retaining
Ring
Low Torque
Centering Springs
and Spacers
Figure 3

8 EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006
Housing
Dust
Seal
Quad
Seal**
Thrust
Bearing
Sleeve
O-ring
Seal**
Bearing Race (2)
Spool
Centering
Springs*
O-ring
Seal
Wear
Plate Drive
Spring
Retaining
Ring*
Pin
O-ring**
O-ring**
Seal
Ring**
End
Cap
Cap Screw
Gerotor
Manual
Steering
Check/Relief
Valve
Plug
O-ring
Timing
Groove
Timing
Groove
Timing
Groove
Round Housing
with End Ports
ExplodedView

9EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006
Round Housing
with End Ports
Parts List
ITEM NO. PART NO. QTY. DESCRIPTION REFERENCE PAGE
1 See Table 4.0 4 Cap Screw, Hex Head 10
2 4993924-XXX 1 Cap, End (Non-load sense, non-STConly)
4 See Table 4.0 1 Gerotor, Sub-assembly 10
5 4993805-001 1 WearPlate
6 4994693-001 1 Drive
9 22853-000 1 Drive Pin
13 4997396-001 2 Bearing Race
14 4996933-001 1 Bearing, Needle Thrust
16 4997708-001 1 Dust Seal
REPLACEMENT PART NO. DESCRIPTION
64456-00 Centering Spring Kit - Standard Torque (contains parts with *)
990170-000 Centering Spring Kit - Low Torque (contains parts with **)
990252-000 Seal Kit - Standard Back Pressure (contains parts with **)
9900256-000 Seal Kit - High Back Pressure (contains parts with **)
9900321-000 Seal Kit - Viton, PM Gerotor(contains parts with **)
9900323-000 Seal Kit - Viton, Steel Gerotor(contains parts with **)
Table 3.0
Round Housing with
End Ports
ACTUAL DISPLAY REFERENCE NO. 4 GEROTOR REFERENCE NO. 29 CAP SCREW
cm3/r[in3/r]Part No. Width mm [in]Part No. Length mm [in]
31.5 [1.92] 4998582-001 7.4 [.290] 4994536-045 44.9 [1.77]
39.5 [2.41] 4998582-002 9.3 [.366] 4994536-050 50.0 [1.97]
50.8 [3.10] 4998582-003 8.3 [.326] 4994536-045 44.9 [1.77]
63.1 [3.85] 4998582-004 10.2 [.400] 4994536-050 50.0 [1.97]
73.8 [4.50] 4998582-005 12.1 [.476] 4994536-050 50.0 [1.97]
100 [6.10] 4998582-006 16.3 [.642] 4994536-055 55.1 [2.17]
120 [7.33] 4998582-007 19.5 [.768] 4994536-060 59.9 [2.36]
Table 4.0
Gerotor

10 EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006
Housing
Dust
Seal Bearing Race (2)
Spool and
Sleeve
Quad
Seal**
Thrust
Bearing
Round Housing
with End Ports -
Disassembly
Disassembly
Cleanliness is extremely impor-
tant when repairing hydraulic
Steering Control Units (SCU).
Work in a clean area. Before
disconnecting the hydraulic
lines, clean the port area of the
SCU. Before disassembly, drain
the oil, then plug the ports and
thoroughly clean the exterior of
the SCU. During repairs, always
protect machined surfaces.
Disassembly
1. Remove the plug and inlet
relief as shown in figure 1.
Note:The manual steering
check is part of the inlet relief
valve. If inlet relief valve is
not present, the manual
steering check is located in
the housing.
2. Remove the four cap screws
and disassemble the SCU as
shown in figure 1.
3. Slide the spool and
sleeve from the housing,
see figure 2.
4. Remove the thrust bearing
and bearing races.
5. Remove the seal.sembly
6. Using a small blade
screwdriver, carefully pry the
dust seal from the housing.
Important: Do not damage
the dust seal seat.
7. Remove the pin that holds
the spool and sleeve togeth-
er, see figure 3.
8. Carefully slide the spool out
of the sleeve.The springs
and retaining ring will stay
with the spool as it’s
removed.
9. Remove the retaining ring
and springs.
Caution:The centering
springs are under tension;
remove the retaining ring
carefully.
Figure 1
Figure 2
O-ring
Seal
O-ring
Seal
Wear
Plate Drive
Spacer
O-ring O-ring
Seal
Ring
End
Cap
Cap Screw
Gerotor
Manual
Steering
Check/Relief
Valve
Plug
O-ring
Dust
Seal
Timing
Groove
Timing
Groove
Timing
Groove
Timing
Groove

11EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006
Standard Torque
Centering Springs
and Spacers
Sleeve
Pin
Spool
Spring
Retaining
Ring
Low Torque
Centering Springs
and Spacers
Reassembly
Check all mating surfaces.
Replace any parts with scratch-
es or burrs that could cause
leakage. Wash all metal parts in
clean solvent. Blow them dry
with pressurized air. Do not
wipe parts dry with paper tow-
els or cloth as lint in a hydraulic
system will cause damage.
Note: Always use new seals
when reassembling hydraulic
steering control units. Refer
to seal kit part numbers on
page 6.
Important: During reassembly
lubricate the new seals with a
petroleum jelly such as
Vaseline®. Also lubricate
machined surfaces and bearings
with clean hydraulic fluid.
10. Install the quad seal:
(see page 12 for 2-piece
seal installations):
• Put one of the bearing
races and sleeve into
the housing.
•Together, the housing and
bearing race create a groove
into which the quad seal will
be installed.
• Hold the bearing race tightly
against the input end of the
housing by pushing on the
gerotor end of the sleeve.
• Fit the quad seal into its seat
through the input end of the
housing. Be sure the seal is
not twisted.
• Remove the sleeve and
bearing race.sembly
11. Lubricate and install the dust
seal (see Figure 4 for correct
seal orientation).
12. Install the centering springs
in the spool. It is best to
install the two flat pieces
first. Next, install the curved
pieces, three at a time.
13. Fit the retaining ring over
the centering springs.
14. Apply a light coating of
clean hydraulic fluid to the
spool and slide it into the
sleeve. Be sure the center-
ing springs fit into the
notches in the sleeve.
15. Install the pin
(see Figure 3).
16. Apply a light coating of
petroleum jelly to the
inner edge of the dust
and quad seals.
17. Put the thrust bearing and
races into the housing.
The thrust bearing goes
between the two races
(see Figure 2).
18. Apply a light coating of
clean hydraulic fluid to
the spool and sleeve assem-
bly and slide it
into the housing.
Important: Do not damage
the dust or quad seals.
19. Clamp the housing in a vise
as shown in Figure 5. Use
just enough clamping force
to hold the housing securely.
20. Install manual steering check
ball and pin into housing, if
no relief valve is present.
21. Lubricate and install a new
o-ring seal in the groove in
the housing.
22. Install the wear plate and
align the timing groove
on plate with the timing
groove on the housing.
Note:The holes in
the wear plate are
not symmetrical.
23. Install the drive, be sure the
slot in the drive engages
the pin.
24. Lubricate and install a new
o-ring seal in the groove in
the wear plate.
25. Install the gerotor and align
the timing groove with the
timing groove in the wear
plate.
26. Lubricate and install a new
o-ring seal in the groove in
the gerotor ring.
27. Lubricate and install a new
o-ring and seal ring in the
groove in the gerotor star.
28. Install the spacer.
29. Install end cap and four cap
screws. Align timing groove
on endcap with timing
groove on gerotor.Tighten
cap screws, in a crisscross
pattern, to 25 -31 Nm
[225-275 lb-in].
30. Install the relief valve/check
if present. Use a new o-ring
and tighten the plug to 17
Nm [150 lb-in].
31. Remove the SCU from
the vise.
32. Check SCU and confirm all
timing grooves are in line.
Note: If timing grooves are
not aligned properly, SCU
will not function.
Round Housing
with End Ports -
Reassembly
Figure 3
Quad Seal
Dust Seal Thrust Bearing
and Race (2)
Figure 4
Figure 5

12 EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006
2-Piece
Shaft Seal
Assembly
Installation
2-Piece Shaft Seal Installation
For installation of
O-Ring 4999650-001 and
Seal 4998312-001
1. Place housing on a flat work
area as shown in figure 13.
2. Lubricate seal and o-ring with
hydraulic oil before installa-
tion.
3. Align sleeve with housing
bore (figure 13).
4. Insert sleeve into housing
bore (figure 14).
5. Place o-ring on plunger (fig-
ure 15).assembly
6. Align seal with plunger cross
section “L” shape of seal
should be upside down (fig-
ure 16).
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 17).
8.
Align plunger into sleeve
until it bottoms out, rotate
1/4 turn (figure 19).
9. While holding sleeve in
housing, withdraw plunger.
10.
Withdraw sleeve.
11. Inspect seal installation.
Seal and o-ring must both
be within shaft seal
counter bore of housing.
Figure 13 Tool No. 600801-001 Figure 14
Figure 16Figure 15 Figure 17
Figure 19Figure 18 Figure 20

13EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006
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 more detailed Information,
contact:
Eaton Corp.
Hydraulics Division
14615 Lone Oak Road
Eden Prairie, MN 55344
www.hydraulics.eaton.com
• Specifications and
performance data, Catalog
No. C-STOV-MC001-E1

© 2006 Eaton Corporation
All Rights Reserved
Printed in USA
Document No. C-STCU-TS002-E1
Supersedes No. C-STCU-TS002-E
November2006
Eaton
14615 Lone Oak Road
Eden Prairie, MN 55344
USA
Tel: [phone]
Fax: [phone]
www.hydraulics.eaton.com
Eaton
20 Rosamond Road
Footscray
Victoria 3011
Australia
Tel: [phone]
Fax: [phone]
Eaton
Dr.-Reckeweg-Str. 1
D-76532 Baden-Baden
Germany
Tel: [phone]
Fax: [phone]