E:T-N | Char-LynnSeries 20 VersaSteer Table of Contents Introduction Io Tag Tools Parts Assembly Drawing ist Gorotor parts Disassembly ‘Assembly Seal Installation Introduction This manual provides service information for Char-.yna® Series 20 VersaStee™ Steering Control Units. Step by step instructions for complete cisassembly, inspection and reassembly of the control unit are given, The following recommendations should be followed 10 insure successful repairs + Most repairs require the removal ofthe control Unit from the vehicle, + Cleanliness is extremely important. ‘+ Clean the port areas thoroughly before disconnecting the hydraulic ines Plug the control unit ports end cover open hydraulic lines immediately after they have been disconnected Drain the oll and clean. the extarior of the control unit before making repairs. Wesh all metal parts in clean solvent. Use filtered, moisture- free compressed air 0 dy the pars, Do not wipe them ary with paper towels of cloth — lint ina hydraulic, system will cause damage Always use new seals, ‘when reassembling hydraulic control units © Lubricate new rubber seals with a petroleum jel before installation + Torque all bolts over ‘gasketed joints, then Fepeat the torquing sequence to meke up for ‘gasket compression Afterall repairs are complete its essential 10 verify the accuracy of control unit repairs on an authorized test stand. 2 EATON Hiydrauicn Sees 20 versie: Pan ad Rest CSTCUTSOOT-E Deceber 204 a2 33.20 1418ID Tag Ordering Parts How to Order Each order must include Replacement Parts the tolowtne, ar Code Label — Launch Date January, 2008 1 Product Number 2. Date Code 3 Part Nome Customer art umber 4 Part Number o 5 Quantity of Pants Sesame Refer to specific pert listings for your Char-Lynn® Month/Day/Year VersaSieer™ Steering Control Unit when ordering Eaton Part Number replacement parts. Listings are available from Eaton Sample tag shows identification When ordering replacement parts, you must include the Port Face following information For additional iterature contact Eaton Hydraulics 14615 Lone Oak Road, Eden Prairie, MN 55344 http:fhydrautis.eaton com Tools ‘Tools Required For Disassembly and Assembly ‘© Screwekriver (102-182 mm [4 in - 6 in long, x3 mm (118 in} ‘wide fat blade) ‘+ 13mm socket for current hex head cap screws + Breaker bar weench ** Retaining «ing pliers tool No. 600810. ‘© Torque wrench (0 Nn [300 Ib-n] capacity ‘+ 16/16 inch Hex key = 11/6 inch wrench Tools: Speci ‘+ Plunger and Sleeve Tool No 600794001* ‘Tons avallable—by special order—through ou sorvice department EATON Hyarutice Series 20 er ee Pay and pai €-SICUTSIO?E December 200¢ 2Parts Assembly DrawingParts Table 1.0 Parts List Series 20 VersaSteer rem REFERENCE MOM _partno. ary. __pescmrion. PAGE {Ses Table 2D _7__Cap Sere, Hox ead __ © asin 0a 3 2anig90m 6 Seal O-ring 728 wm BB a 1D eat ‘ 1 Gera Subassenbly -_ 5 1 Pie, Spazer — é Dre z 1 Howwig aoe a 1 Comal Seeve 1___Convel Spot 5 a ‘Dor8 Bal, Coecksirniza0 in] OD. _ w 1 Pin Genering 1 1 Spt, omering 1__Spting Camering ee specifications) — @ 1 Bearing, Needle Tt 2 2 Besving Race —_ ie 10g _— is “bus Seah ag ® bing - o 1 Rewinng fing 2 1 Piston, Guide Sig - 2 Compression Spring B_maneow 2 oom 06 2 ing ___sooao, 1 Piston — 2500 2 Bal - 2 a8 2 Pin, fal Ss __ s-000 rece cael a ‘Sousa, Pat, Wate 5 espg7 oT Wate Sik Sessa, Pit, Vale —_ 5 __wau 000 1 ‘Sealing _— am. 1 Woshw, Bap EATON Myerautce Sri 20 raster Pane ond Rapa © SYCUTSOOT- Oaambe 2004Parts Gerotor Table 2.0 ACTUAL DISPL. REF. NO. 4 REF. NO. 1 emt GEROTOR CAP SCREW Ginvie]___PART NO. Length mmiin] PART NO. LENGTH mmfin} a (731.005 e501 — ‘ages 18 1093. ie fes-—aeta —— tate] lore) 018 ess) 161 (87) 0-07 86) 166-018 #5 03.35) ipa wera 095) aie] asters 4 SOAS a) ener 1 ToL] Sioa) tener) ht eas a10 105082 ‘eae ese a aia Neat Sica sera — es ai1 150082 2s) een rasan) see eggs) _as-023 75 . EATON Hydraulics Stes 10 Vortec: Pa and pss CSTCU TSIOY-£ December 204Disassembly Cleanliness is extremely 1. Clamp unit in vise, impostant when repairing a meter end up. Ciarmp steering control unit, Work lightly on edges of port inaclean area. Before dis face sides (see figure!) ‘connecting lines, clesn port Use protective material ‘area of unit thoroughly. Use on vise jaws. Housing 3 wire brush to remove distortion could result foreign material and debris laws are overtightened. from around exterior joints of the unit. We recommend that you keep the unit in @ vise during disassembly. Follow the clamping procedures: explained throughout the manual Gerotor (Meter) End Ant: Cavtation Vales located under these ‘wo cap stews! Note: Steering control units with anticavitation valves require special handling in eae both disassembly and Ball reassembly Ball valves (2) Check ‘can end up in @ cavity in the housing were they are not supposed to be These unit must be disassembled and reassembled in the vertical position; removal of anti-cavitation valves is SCU End Cap outlined in step 26. Top View Figure 1 [EATON Hydraulics Se Pans and Rope STCU-TS0H7.£ Daearte 2006Disassembly 2. Remove MB-1.6 in. cap 3. Remove end cap. 4. Remove seals Note: All Series 20VersaStear™ steering control units Seal, Ring have a low slip sealed ore gerotor star, this unit srt! inculdes ating seal and a back-up ring {remove ‘these parts if applicable! ma Figure 2 erator 5. Remove gorotor (meter a Be careful not to drop star. (Meter 6. Remove seal from Seal valve plate 7. Remove valve plate oo 8 Remove seal from valve SIA Seal ——— Valve SA Figure 3 [EATON Hydrouice. Serie 20VresSier Pars nd Reps CSTEU-TSOO7-£Daarbo 206Disassembly 9. Remove valve Sub- assembly 10. Remove seal from valve piste. 11. Remove valve plate Remove seal ror ‘spacer plate 13. Remove spacer plate 14, Remove seal from housing Figure 4 [EATON Hydration Soe 20 verse: Pans anc Rapa CSICUTSOIT.E Oacambe 208Disassembly Attention: Do not bind spool and sleeve in housing. Rotate spool and sleeve assembly slowly when removing it from housing. 18. Pull drive and twist 10 Note Hiden Pin seninon this init eles before these pars ‘uly remove SPISL drive ‘assembly from Seed ane pista be housi incon op an lockup cn oz he 9 a Seadoo Festi ue erly i sale ‘pn ads request has se te Ch. erator Ste ‘ad Spied Dive Ego fe 1 Engage tot wth spine eno pel Teal 4 4 17 Protest get star nha wth stop towel — hol armor san epned ove rom wig i U Comsrng Sing eae ao) 18 Twist lt compress omring sping fool 1" radial Co: COW, daseasing the al ¢ 4 Sartre cova g soot tobe renner longwh re spzl nd Me Seve to ct agen) pin bearing eco tanng in, and nde tht eng (enn aes ean tng nani ts bang, on range Cann sping sn a) —_ Toa : a 18 With dive held ttonay and ceing = sen emoressed, cil push hese ‘poo ar Sieve tal eke eppiade). ike, Fi, Bearing ace retaining Ring Neadie Tus Bearing, nd ‘stood esting ae assombid pars out of oaing Figure 5 1 EATON Hyaroutice Ser and Rept STOU-TONT-E Dacambe 2008Disassembly Housing Hewsing aro Sar Splines one /. Me le / Ae) face Beating 20. Remove the thrust bearing race and needle & thrust Bearing Figure 6 21. Remove the retaining ring (use retaining ring plots Eaton part no {6006 1O}or equivalent, bearing race, centering spring, pin, dive, spool, sleeve, and ball checks if eoplicable 22, Do not remove any valves other than Dive Sleeve Coneing Spring Rate, Bening \ ~ manual steering check valve balls and anticavitaton valve assembly. All other valves are factory preset and are nor-serviceabla Figure 7 EATON Hydrate, Sores 20VrsSte: Pars and apse CSTCUTSOO-E Oncor 206 uDisassembly Soda Straw 26. Insert wo soda straws, an fone in each of two thread {Soda Stave) Mot (oat nd ed holes, as a safety meas- Ure for removal of two, small ball check valves and roll pins (correct threaded holes identified initustra- tion righ}. Remove hous ing from vise, tt the hous- Ing and bring the port fece ‘upward. Continue turning the housing unt the rol pins and ball checks slide through the straws from the meter (Geroton) end of ‘Ant-Cavitation the housing. Valves — Insert nda Straws 2), one ito each ofthese ‘two threaded holes. 27. Carefully remove the shaft Backup Waser seal These two parts may or ° may not stil bein the ‘ng housing. These parts include I an o-ring and L-shaped seal “Ob. ring, 28 Using a thin blade screwdriver, carefully pry the ‘dust seal from the housing. ‘Seal (2 Piece) Do not seratch seal groove with serew driver Important: Do not darnage the dust seal seat 11/16" Hex Key \ Ss \ \ PO soi ein \ O-ring 2 [EATON Hydraulics Sais 20VaraStet Para RepieCSTCU-TSOULE Decembe 706Assembly Assembly Cleanliness Recommendations Check all mating surfaces. Replace any pars that have scratches or burrs that could cause leckage 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 al old seals with now seals, Do not use excessive lubricant on seals for meter section Refer to parts ists covering your steering control unit when ordering replacement parts 1. Place housing on a flat ‘work area on a clean lint free cloth 2 Install pressit 24,9 mm|.98 in. ID seat in housing with metal suface of seal facing ‘toward housing (figure 11) Figure 11 Friting \ Piston \ Valve SIA x 3. Reassemble vale paris, ue) vwaith new o-rings on plugs (See figure 12), Piston, Guide Spring Torque Fittings to 31-45Nm [23-33 lb-ft) Oring Note: The fittings included in the : valve assembly are critical in Figure 12 the operation of the valve, and must not be switched with another style. [EATON Hydraulin Swris 20 VorsStee Pars an Rapa CSTCU.TSODT€ Dacember 204 3Assembly 2-Piece Shaft Seal Installation For installation of corting, 4999651-001 and Seal 9332-000 4. Place housing on @ fiat work area as shown in figure 13. 5. Lubricate seal and o-ring with hydraulic oi before installation 6 Align sleeve with housing bore {figure 13) 7. Insert sleeve into housing bore {Figure 14) 8. Place o-ring on plunger (Figure 15) oo! No. 600792-001 9. Align seal with plunger cross section ‘L” shape (of seal should be upside down ffigure 16) Figure 16 “ [EATON Hydraulics Sats 20 Verte Parte an Rep CSTCUTSDETE Dace 204Assembly 2-Piece Shaft Seal Installation 10. Push seal onto plunger Lip of seal should be ‘between o-ring and ‘lunge No gap should ‘exist between oving and seal (igure 17), 11. Align plunger with sleeve (figure 18) 12. Push plunger into sleeve ntl it bottoms out, rotate 1/4 turn (figure 19) 13. While holding sieeve in housing, withdraw’ plunger 14. Withdraw sieeve 18. Inspect seal installation Seal {and o-ring must both be within shaft seal counter bore of housing figure 20) 2) 16. Clamp housing in vice (figure 21) Figure 21 [EATON Hyérauin Saves 20 Vester Pas an apa STCU6007- Drewmbe 2008 6Assembly 17- Hf applicable install 6 check balls into sleeve with coating of petroleum jlly 18 Assemble spool and sleeve carefully so that spring slots line up at the same end. Rotate spool while siding parts together. Test for free rotation. Spool should Fatate Smoothiy in sleeve with fingertip force applied at splined end. Align spring slots (Figure 22) in spool and sleeve and stand parts on end of bench 19. Hold spo! and slaove assembly firmly and Centering twist centering spring 10 ontrin pring Free assemble pee 20. Assembly 1 beering race ‘onto spo! 21. Install retaining ring using Eaton too! 600610 Housing Vertically Mounted ace, Bearing fr equivalent 7 22 Insert pin through spool Fing Retaining and sleeve assembly through hole in drive, eee \ = —— Retaining Ue Ta] ——S — Spoot Bal, Check or Pin Figure 22 e EATON Hydraules Sores 20 Vesta Pars an Repu C SICU.TSOGTE December 208Assembly 23. Apply alight coating of petroleum jelly to the inside diameter of the previously mounted dust seal in the housing 24. Apply alight coating of petroleum jelly o the needle thrust bearing, second bearing race, and three part shaft ‘seal, Position each part onto the spool as shown in enlarged section drawing below. The needle thrust bear ing goes betweenthe two bearing races and must be centered around retaining ring 25. Apply a light coating of clean hytraulic fluid to the spool and sleeve assembly and slide it into the housing [see steps 26-31) Important. Do not damage the dust or shaft seals. Spun and Sooo tal chcks i eplede} Dre, Pin, Baring ace, a earing ing Bowing, Neale Thrust ace, Bearag Attention: While inserting spool and sleeve assembly into housing, make sure parts do not tit 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. Housing wih dust Sel & Sha Seal Fetainng irs Note Needle Thrust Bearing MUST Be Contre Arund Patan ing Use Patleur dele Het Paso Pace Figure 23 EATON Hverauice Seve 20 VraStet Pr and asi CSTCUTSON7 December 204 ”Assembly 28. Protect gro tar and hand with shop ‘wel — hold geotor star and splined end Housing of veto keep it fom tuning 7. sort too hough busing, engage with splined end of spool assombad isda of sleeve slong wath ball chock appliate, centering sping, dv, pn, essing race, retaining ng, needle thst fo Dearing, second baring ace Twist tol 9 = one 7 HCO? ee sunset Noe his unit inthe haiontal pasion oop pin nearly horizontal Hf tension on this pin'sreleased befor these pats ae fully ‘engaged and the pin is ot hviantalthe pin ay ‘ar drop and lockup can occur ike a deadbolt & oe eC 28 Keep caneing sping compressed, and / Z. ‘carefull insert these assembled parts inta Povsing 00 NOT FORCE Baaing oes, retain rig, eee thst ering. not ‘shown on drawing at eft Cantering ‘sping shown compressed} a ts eS SMC ¢ fe 29 fetes center ping teson ey g Remove gertor star Gerotor Star Tool 31, Remove tol Note: Check to insure that spool and sleeve are flush or “el \ Sightly below 14 hol surface ot housing ‘tention: Clean upper surface ‘of housing by wiping with palm Of clean nend. Clean each of the fiat surfaces of meter sec- mB ton parts in similar way just before reassembly. Do not use cloth or paper to cleen surfaces Figure 24 ™ [EATON Hydraulics Soe 10 reste Pa re Rape CSTEU-TSOD7-€ Desde 204Assembly 32. Lubricate and instal 72,6 mm {2 86 in ID seal in housing ‘33, Install spacer plate ‘Align bolt holes in spacer plate with tapped holes In housing 34. Lubricate and install 72.6 ‘mm (2 86 in JID seal in spacer piste 35. Install valve plate 36. Lubricate and instal 72,6 sm {2.88 in| 1D se in valve plate ‘37. Install valve S/A, see figure 25 for proper, alignment. Seal ‘38. Lubricate and instal 72.6 Aignmest rm {2.86 in JID seal in oferance — acer Plate Bolt Hote valve S/A, ‘Spacer Pat Bolt Hole 39. Install valve plate (Port Face Side) 40. Install back-up ring and sealring in gerotor star. 4A Lubricate and install 72.6 mm {2.86 in| ID seal in valve plate 42. Install gerotor, Screw, Cap, Hex Head Cop. 43. Lubricate and install 72,6 mm [286 in J ID seal in gerotor (meter) — {44 Install end cap on gerotor, aligning holes Groove evoss section vw/tings EATON Hygrolice Sona 20VereSte Part an fapale CSTEU'TSOON- Dasamoer 206 1”Assembly 45 Install 7 dry cap screws in ‘end cap. Pretighten cap screws 10 17Nm [160 Ibn} then torque screws to 28-34 Nm [250-300 Ibn] in Sequence shown in figure 27 ton HE Lane Ot oat en Pie, Mat Usk Tw. 9329079200 ‘oor ow aes anc Exton Deven Road Footy Verona 301 a Tet (1) 3019 az Fac 1138185714 E:TeN | Char-Lynn etn Dr-Redewag i 1 17857 Bad Ban Ter He} axz0 (872162788