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Power Steering

Steering Control Unit (SCU) 5 Series


Steering
Parts and Repair Information
Control Units
001

Square Housing
with Side Ports

Round Housing
with Side Ports
PR
LE
T

Round Housing
with End Ports
Series 5
Steering
Control Unit
Table of Contents

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

Introduction
This manual provides service The following recommendations • Drain the oil and clean the After all repairs are complete it
information for Char-Lynn® should be followed to insure exterior of the control unit is essential to verify the accura-
Series 5 Steering Control Units. successful repairs. before making repairs. cy of control unit repairs on an
Step by step instructions for • Most repairs require the • Wash all metal parts in clean authorized test stand.
complete disassembly, inspec- removal of the control unit solvent.
tion and reassembly of the con- from the vehicle.
trol unit are given. • Use filtered, moisturefree
• Cleanliness is extremely compressed air to dry the
important. parts. Do not wipe them dry
• Clean the port areas thor- with paper towels or cloth –
oughly before disconnecting lint in a hydraulic system will
the hydraulic lines. cause damage.

• Plug the control unit ports and • Always use new seals when
cover open hydraulic lines reassembling hydraulic control
immediately after they have units.
been disconnected. • 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.

2 EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006
General
Information
Ordering Parts

How to Order Each order must include Bar Code Label — Launch Date June, 1999
Replacement Parts the following:
1. Product Number Customer part number
2. Date Code or base unit number if it
has a column or valve
3. Part Name
assembled Eaton Corp. Hydraulics Div.
Eden Prairie, MN 55344

4. Part Number
5. Quantity of Parts Month / Day / Year
Refer to specific part listings
for your Char-Lynn® Steering Eaton Part Number
Control Unit when ordering
replacement parts. Listings are
available from Eaton. Sample
tag shows identification.
For additional literature contact Port Face
Eaton Hydraulics at:
14615 Lone Oak Road
Eden Prairie, MN 55344
http://hydraulics.eaton.com

Tools Tools Required: Special Tools:


• 10 mm Socket (13 mm Socket • Plunger and Sleeve Tool (two-
for End-Ported Units) piece seal) No. 600801-001*
• 7/8 in. Socket * Tools available—by special order—
• Torque Wrench through our service department.
(31 Nm [275 lb-in] Capacity)
• Small Blade Screwdriver

EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006 3
Round and
Square Housing
with Side Ports
Exploded View

Thrust
*Round housing shown,
but applies to square O-ring Bearing
housing also. Seal** Quad
Housing Seal**

Bearing
Dust Race (2)
Seal
Check
Ball O-ring**
Plug

Low Torque
Centering Springs*
Manual Steering
Relief Valve O-ring**
Plug

O-ring** Drive
Standard Torque
Centering Springs*
Wear
Plate
Sleeve

Pin Cap
Screw
Spool Gerotor (7)

Spring
Retaining
Ring* End
Cap
O-ring
O-ring** Seal
Seal**
Ring**

4 EATON 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

Table 1.0
Round and Square
Housing with Side Ports

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 Wear Plate
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 2.0
Gerotor

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]

EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006 5
Round and
Square Housing
with Side Ports -
Disassembly

Disassembly Disassembly
Cleanliness is extremely impor- 2. Remove the plug and 6. Using a small blade screw- 9. Remove the retaining ring
tant when repairing hydraulic manual steering check driver, carefully pry the and springs.
Steering Control Units (SCU). as shown in figure 1. dust seal from the housing. Caution: The centering
Work in a clean area. Before Note: The manual steering Important: Do not damage springs are under tension;
disconnecting the hydraulic check may be a check ball or the dust seal seat. remove the retaining ring
lines, clean the port area of the a check/relief valve. 7. Remove the pin that holds carefully.
SCU. Before disassembly, drain 3. Slide the spool and sleeve the spool and sleeve togeth-
the oil, then plug the ports and from the housing, see er, see figure 3.
thoroughly clean the exterior of figure 2.
the SCU. During repairs, always 8. Carefully slide the spool out
protect machined surfaces. 4. Remove the thrust bearing of the sleeve. The springs Cap
and bearing races. and retaining ring will stay Screw
1. Remove the seven cap with the spool as it’s End
screws and disassemble the 5. Remove the quad seal. Cap (7)
removed.
SCU as shown in
figure 1. Seal
Ring
Gerotor

Wear
Plate Drive
O-ring
Figure 1 Seal
O-ring
O-ring

Anti-Cavitation Valves
(located under these two cap screws)
O-ring
Seal
O-ring
Plug
Eaton Corp. Hydraulics Div.
Eden Prairie, MN 55344

Manual Steering
Check/Relief Valve

Port Face

Spool and Sleeve

Thrust
Bearing
Housing Quad
Seal**

Figure 2 Low Torque

Dust Bearing Race (2)


Seal

6 EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006
Round and
Square Housing
with Side Ports -
Reassembly

Reassembly Figure 4 19. Apply a light coating of


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

Standard Torque
Figure 3 Centering Springs
and Spacers

Sleeve

Spring
Retaining
Ring
Pin

Spool
EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006 7
Round Housing
with End Ports
Exploded View

Thrust
Quad Bearing
O-ring
Timing Seal** Seal**
Groove
Housing

Dust
Bearing Race (2)
Seal

Wear
Plate
Drive
Timing
Groove
Centering
Springs*

Sleeve

O-ring
Seal

Spool Timing
Groove
Pin
Cap Screw
Gerotor Seal
Ring**
Spring
Retaining O-ring
Ring*

End Manual
O-ring** Cap Steering Plug
O-ring** Check/Relief
Valve

8 EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006
Round Housing
with End Ports
Parts List

Table 3.0
Round Housing with
End Ports

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-STC only)
4 See Table 4.0 1 Gerotor, Sub-assembly 10
5 4993805-001 1 Wear Plate
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 4.0
Gerotor

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]

EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006 9
Round Housing
with End Ports -
Disassembly

Disassembly
Cleanliness is extremely impor- 1. Remove the plug and inlet 4. Remove the thrust bearing 8. Carefully slide the spool out
tant when repairing hydraulic relief as shown in figure 1. and bearing races. of the sleeve. The springs
Steering Control Units (SCU). Note: The manual steering 5. Remove the seal.sembly and retaining ring will stay
Work in a clean area. Before check is part of the inlet relief with the spool as it’s
disconnecting the hydraulic valve. If inlet relief valve is 6. Using a small blade removed.
lines, clean the port area of the not present, the manual screwdriver, carefully pry the
dust seal from the housing. 9. Remove the retaining ring
SCU. Before disassembly, drain steering check is located in and springs.
the oil, then plug the ports and the housing. Important: Do not damage
the dust seal seat. Caution: The centering
thoroughly clean the exterior of 2. Remove the four cap screws springs are under tension;
the SCU. During repairs, always and disassemble the SCU as 7. Remove the pin that holds remove the retaining ring
protect machined surfaces. shown in figure 1. the spool and sleeve togeth- carefully.
er, see figure 3.
Disassembly 3. Slide the spool and
sleeve from the housing, End
see figure 2. Timing Cap
Figure 1 Groove

Timing
Groove
Gerotor Seal
Cap Screw
Ring

O-ring
Wear
Timing
Plate
Groove Drive
O-ring
Timing Seal
Groove
Manual
O-ring O-ring Steering Plug
Check/Relief
Valve
Spacer
Dust
Seal

O-ring
Seal

Spool and
Sleeve

Thrust
Bearing
Quad
Figure 2 Seal**
Housing

Dust
Seal
Bearing Race (2)

10 EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006
Round Housing
with End Ports -
Reassembly

Reassembly Figure 4 18. Apply a light coating of


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

Spool

EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006 11
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). Figure 13 Tool No. 600801-001 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. Figure 15 Figure 16 Figure 17
11. Inspect seal installation.
Seal and o-ring must both
be within shaft seal
counter bore of housing.

Figure 18 Figure 19 Figure 20

12 EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006
How to Order For more detailed Information,
Replacement Parts contact:
Each Order Must Include Eaton Corp.
the Following: Hydraulics Division
1. Product Number 14615 Lone Oak Road
Eden Prairie, MN 55344
2. Date Code
www.hydraulics.eaton.com
3. Part Name
• Specifications and
4. Part Number performance data, Catalog
5. Quantity of Parts No. C-STOV-MC001-E1

EATON Char-Lynn Power Steering Control Unit Series 5 Parts and Repair C-STCU-TS002-E1 November 2006 13
Eaton Eaton Eaton
14615 Lone Oak Road 20 Rosamond Road Dr.-Reckeweg-Str. 1
Eden Prairie, MN 55344 Footscray D-76532 Baden-Baden
USA Victoria 3011 Germany
Tel: 952 937-9800 Australia Tel: (49) 7221 682-0
Fax: 952 974-7722 Tel: (61) 3 9319 8222 Fax: (49) 7221 682-788
www.hydraulics.eaton.com Fax: (61) 3 9318 5714

© 2006 Eaton Corporation


All Rights Reserved
Printed in USA
Document No. C-STCU-TS002-E1
Supersedes No. C-STCU-TS002-E
November 2006