Hidraulic Fluid Reservoir System 1

8/8/2019 Hidraulic Fluid Reservoir System 1

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HYDRAULIC FLUID RESERVOIR SYSTEM No.1 and SYSTEM No.2

OVERHAUL INSPECTION WORKSHEET

JOB NO.

CUSTOMER

COMPONENT Hydraulic Reservoir System

PART NO.

SERIAL NO.

TSN/TSO

REFERENCE

NO. JOB DESCRIPTION ACTION TAKEN MECH INSP

NOTE : - Products to be used are given in the List

of Products..

1. Removal and Dismantling of System I Hydraulic Reservoir

Disconnect tubing (8, fig.1) connecting theHydraulic Reservoir (5) with pump (1) (fc.Disconnecting point).

Take away lock spring (4) together with safety cap(2).

Remove the locking wire of relief plug (3), unscrew

relief plug (3) and simultaneously collect the oilwhich will flow from the disconnecting point.

Loosen hose clip (6) and pull off hose (7).

Unscrew tubing (9, 10) and tubing (8) from thehydraulic reservoir (5), using wrench 105-45051W10.

NOTE:Secure the hydraulic reservoir against tilting or falling down before you unscrew the last hex screw.

Take away hex screw (4, Fig.2) together with thewashers (3)

Lift off hydraulic reservoir (1), together with bracket(2) from the A1 alloy frame.



PAGE 2 OF 9

HYDRAULIC FLUID RESERVOIR SYSTEM No.1 and SYSTEM No.2

OVERHAUL INSPECTION WORKSHEET

JOB NO.

CUSTOMER

COMPONENT Hydraulic Reservoir System

PART NO.

SERIAL NO.

TSN/TSO

REFERENCE

NO. JOB DESCRIPTION ACTION TAKEN MECH INSP

NOTE : - Products to be used are given in the List

of Products..

Special tools and equipment to be used are listed on pages 901 and 902.

1.2 Dismantling of the hydraulic reservoir

Remove the wire lock.

Screw out hex screws (4. Fig.3) and take awaywashers (3) and barcket (2).

Remove hollow screws (1,8, Fig.4, together withsealing washers (2, 6) and banjo bolts (3, 7), andthe double nipple (5) with its sealing ring (4)

Discard sealing rings (2, 4, 6)

2.Removal and Dismantling of System II Hydraulic Reservoir

2.1 Removal of the Hydraulic Reservoir

Disconnect tubing (8, Fig.5) connecting thehydraulic reservoir (5) with pump (1) (cf.Disconnecting point)

Take away lock spring (4) together with safety cap(2)

Remove the locking wire of relief plug (3, Fig.5),unscrew releif plug (3) and simultaneously collectthe oil which will flow from the disconnecting point

Loosen hose clip (6) and pull off hose (7)



PAGE 4 OF 9

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PAGE 6 OF 9

Ð Y

Ñ Ò A

Ó Ô IC

Õ Ô Ó I

Ñ

Ò ESE

Ò V

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Ò SYS

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Ù o.

Ú and SYS

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Inspection,Ý

epair , or Ý

eplacement

NOTEÞ he f ollowing par ts must always

ß

e discarded and replaced ß

y new par ts

à

.á eassembly of the System I/II reservoir

â ã

Þ E

y All par ts that have been reworked must again be cleaned in the ultrasonic bath bef ore reassembly.

y ä

hen installing å

-r ings, back up r ings, Glyd r ings and sealing r ings, do not use tools with sharp edges or rough sur f aces.

æ ake sure that the

å

-r ings fit evently and are not inver ted.ä

et the wear par ts mentioned above with hydraulic oil

ç

item è è é ê

bef ore installing them.

ë

.è

Installation of the filter cover with filter , contamination indicator and ³ì

ype í

ä

æ

´ check valve

NOTE Install the î

-r ing f or the control piston, using conical dr iftï ð ñ ò

-45041 ó

15)

Installî

-r ings ï

1,ô

ig.õ

4)

Caref ully install control piston ï 5) in filter cover

ï

ö

) and make sure that the long shaft is to the r ight of stop pin ï

14).

Install washer ï

÷

) and screw in plug ï ø ).

Install compression spr ing ï 4) on control piston

ï 5),

isntall wahser ï

ù

) on screw plug ï õ ) and screw in the

plug ï õ ).

Install stop pin ï 14) with compression spr ing

ï 15) and

screw in plug ï õ )

Install stop pin ï 14) with compression spr ing

ï 15) and

screw in plug ï

16).

ú

î û

Ey

ü

he matching washer ý 11) must be of such thickness that the stop screw, when tightened, is just below

the cylinder edge of the filter cover .

y ü

he check valve is set dur ing the test operations

Install the check valve in the correct sequence ý

þ

to 13).

Installÿ

-r ings ý

4,

ig.¡

5) on the filter cover ý

3).

¢ ÿ ü

E As the reservoir is going to be tested, a dummy filter ý 105-45051

£

þ

) is installed instead of the filter element.

Caref ully install filter cover ý 3) in the reservoir and

f asten with washers ý ¡ ) and hex screws

ý 1).



PAGE 7 OF 9

¤ Y

¥ ¦ A

§ ̈IC

© ¨ § I

¥

¦ ESE

¦ V

I

¦ SYS

E

o.1 and SYS

E

o.

NOTE Locking wires will be attached after the test.

5.

Installation of the filter with contamination indicator and ³

ype

P´ check valve.

NOTE Setting of the check valve and isntallation of a matching washer 6) will f ollow dur ing the tests.

Install the contamination indicator and check valce in the correct sequence

ig.

6)

NOTE

he locking wire will be attached after the test

Install

-r ings

3,

ig. !

) on filter cover

4).

NOTE As the reservoir is going to be tested, a dummy filter 105-45051

" # ) is installed instead of the filter element.

Caref ully install filter cover 4) in the reservoir and

f asten with washer

5) and hex screws

6)

NOTE Locking wires will be attached after the test.

5.3 Installation of the low pressure saf ety valve

ig. $

)

Install the low-pressure saf ety valve in the corrcetsequence

ig. $

)

%

Ey Setting the low-pressure saf ety valve and matching of the washer

&

3) will be made dur ing the tests.

y '

he locking wire will be attached after the tests.

5.4 Installation of the low-pressure piston and piston rod.

Install( -r ing

& 5,

) ig.

0 1 ) and back

( -r ing

& 4) in screw

plug & 3).

Install( -r ing

& 0 ) on screw plug

& 3). Screw-in screw plug

& 3) as f ar as it will go and lock with circlip

& 1).

Isntall( -r ing

& 1,

) ig. 30) and back up r ing

& 0 ) in housing

& 3).

NOTE Applicable only to piston with expander-spr ing

Install2

-r ing 3

1,4

ig. 31) in the psiton.

Inser t expander spr ing 3 5 ) and Glyd r ing

3 3) in the upper

piston groove.

Inser t back-up r ing 3 4) and

2

-r ing 6

5) in the lower piston

groove.

NOTE Applicable only to r islan-coated pistons.

Inser t2

-r ings 3 1, 3

4 ig. 13a) and back up r ing

3 5 ) in

piston.

NOTE Applicable to all types of hydraulic reservoir .



PAGE 8 OF 9

7 Y

8 9 A

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A LUI

8

9 ESE

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9 SYS

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ED

E o.1 and SYS

C

ED

E o.

F

InstallG

-r ing H

1,I

ig. 32) and back up r ing H

2) as shown

in view A.

P G

Q

E

R

o not tilt piston H 4,

I ig.33) when installing it in housing

H 5).

H

R

amage to the sliding sur f aces and sealing elements)

Install piston H 4) in housing

H 5).

R

egrease threads of piston rod H S

) and sleeve H

2) with solvent

H Item

P o. 201).

Inser t piston rod H S ) into housing

H 5) through bottom

opening and install washer H 3).

Apply locking compound H Item 683) to threads of piston

rod H S ) and sleeve

H 2), screw in sleeve

H 2) tightly.

H Use holding-up tool 105-45051W3 at the piston rod)

InstallG -r ing

H 6) in the threaded groove and screw on

cap H 8).

CAUTION: T

U

EN TIGU TENING THE

V

EW

IEF PW UGS

X

1Y

, HOLD PISTON V OD

X ̀

Y

AT THE PV ODRUDING HEX TO PREVENT IT

FROM a

EING UNSCRET

ED IN THE PROCESS.

b

ighten relief plug c 1).

d e

b

EWhen the reservoir has been tested

c Section 6), the protective cap

c 1,

f ig. 34) with lock wire

c 2) is mounted.

f asten cover

c 4) with two screws initially.

Install scraper r ing c 3) in cover

c 4).

Put on cover c 4) and f asten with two hex screws

c 6)

and washers c

5).

5.5 Assembly of the connecting components.

1- System Ic f

ig.35)

Screw-in hollow screws c 1, 8) with sealing r ing

c 2, 6) and ban jo bolts

c 3,

g ).

Screw-in double nipple c 5) with sealing r ing

c 4).

2- System IIc f

ig. 36) Screw-in double nipples

c g , 8) with sealing

r ings c 6,

h ).

Screw-in hollow screw c 5) with sealing r ing

c 3)

ban jo bolts c

4), screw nipple c

2) and sealing r ing

c

1).

6 b

esting the System I/II hydraulic fluid reservoir

NOTE When the required values or reactions cannot be obtained dur ing the test, look up the reason in the table in section

g and remedy, if necessary.



PAGE 9 OF 9

i Y

p q AULIC

r LUI

p

q ESE

q V

s I

q SYS

t

Eu

v o.1 and SYS

t

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v o.2

6.1 w unctional test of the ³

w WM´ filter contamination indicator with bypass valve

x w ig. 38)

y

est eequirements:

ummy filter 105-45051 W9 has been installed; the hydraulic fluid reservoir is empty.

Apply a pressure of 2.0 bar to

.

equirement; Control piston of filter contamination indicator must not begin to extent.

Slowly increase pressure at

, up to 4.3 bar as a maximum.

equirement: control pir ton of the filter contamination

indicator must begin to extent.

Increase pressure to 4.4 bar and reduce again.

equirement; Control piston of filter contamination

indicator must extend all the way out and remain in this position.

W A

I

G:

y

E S

y

P PI

WILL BLOCK y

E CONTROL

PISTON.

O NOT w ORCE IN THE CONTROL

PISTON.

Apply a pressure of 4.4 + 0.4 bar to ³R´ to 4.4 + 0.4 bar .

Reaction: The bypass valve must open, oil flows in the

reservoir and comes out at por t ³S´.

Pull out filter cover x 3,

w ig. 4) after having removed the

hex screws x 2) and washers

x 1).

Screw out the dummy filter x

4) x

105-45051 W9).

Screw filter elementx 5) with O r ing

x 6) in the filter cover

by hand.

Check the position of the O

r ings x

, 8) in the r ing grooves of filter cover x

3).

Install filter cover x 3) in the housing and f asten with hex screws

x 2) and washers

x 1).

Push in the indicator button x

9) of the filter contamination indicator .



PAGE 10 OF 9

HY R AULIC

LUI

RESERVOIR SYSTEM No.1 and SYSTEM No.2

6.3 High-pressure test

ig. 42)

Test requirements:Cover removed

Close por t in ³S´ with a pressure seal cap.

NOTE In order to fill the reservoir place it in such a position that filling point ³R´ is ver tical.

ill the reservoir with oil, close filling point ³R´ with a pressure seal cap and repalce the reservoir in the position shown in the drawing.

Apply a pressure of 103 bar at ³Pv´ and bleed the system by means of the relief plug.

Apply a pressure of 103 bar f our times to the system.

Requirement: NO oil must leak at the piston seal.

Apply a pressure of 155 bar f or 5 minutes to the system.

Requirement: No oil must leak at the piston seal

6.4 Test pressure on the return line

ig. 43)

Close por t ³S´ with a pressure seal cap.NOTE: Bleed the reservoir well dur ing the pressure increase.

Slowly apply a pressure of

.4 bar to return line ³R´ f or three times.

Requirement: Oil must not leak at por t ³Pv´ and the piston seal.

Apply a pressure of

.4 bar to return line ³R´ f or 10

minutes.

Requirement: No oil must leak at por t ³Pv´ and at the piston seal.

rop f ormation at the low pressure saf ety

valve

1, ig. 43) is permissible.

6.5 Testing of the Low-Pressure Saf ety Valve

ig.43)

Close por t ³S´ with a pressure seal cap.

Gradually increase pressure at ³R´ por t f rom zero to

.5 bar and back to zero, 3 times.

External leakage is not allowed. At ³PV´ and at low-pressure saf ety valve, no leakage is allowed.)



PAGE 11 OF 9

HY R AULIC

LUI


Increase pressure at ³R´ por t to 8.5 bar

luid must flow f rom low-pressure saf ety valve. Low-

Pressure saf ety valve is open).

Reduce pressure at ³R´ por t to

.5 bar .

Leakage of only a f ew drops is allowed f rom low-pressure saf ety valve. Low-pressure saf ety valve is

open).

ecrease pressure at ³R´ por t to 5.4 bar .

At the low-pressure saf ety valve, no leakage is allowed.

6.6

ynamic Leak Test at the Position

ig. 44)

Attach cover and fix with two screws to prevent

contamination.

Connect por ts ³R´ and ³Pv´ to test stand.

Close por t ³S´ with a pressure seal cap.

Apply a pressure of

bar to ³R´.

Reaction: The Piston travels downwards.

Reduce the pressure at ³R´ to a maximum of 1.8 bar and increase the pressure at ³Pv´ to a maximum of 103 bar .

Reaction: The piston travels downwards.

Let the piston travel 25 times againts the upper and lower stop.

Remove cover .

Requirement: after 25 f ull psiton travels, there must not

be more than 1 drop of leak oil on the housing wall.

6.

r ictional

orce Test between Piston and Housing

ig. 45)

Close por t ³S´ with a perssure seal cap.

Connect por ts ³Pv´ and ³R´ to test stand.

Apply a constant pressure of 103 bar to ³Pv´



PAGE 12 OF 9

HY R AULIC

LUI


Requirement: piston 1) tarvel downwards.

Apply a pessure to ³R´ approximately) 1.4-1.

bar)

untill piston comes to a standstill.

Position dial indicator 1,

ig. 46) at the relief plug

3).

Increase pressure at ³R´ so that piston star ts to move upward, simultaneously measure the pressure at ³R´.

Reduce pressure so thhat piston star ts to move downward, simultaneously measure the pressure.

Requirement: The diff erential pressure must notexceed 0.4 bar .

6.8 Pressure test at the suction por t

Test requirements:Reservoir filled, cover attached with two screws.

Close por t ³R´ with a pressure seal cap.

Connect por t ³Pv´ with the test stand.

Apply a pressure of 103 bar to ³Pv´

Reaction: Pressure at the suction por t ³S´ must be beetwen 1.4 and 1. 5 bar .

1.1 EQUIPMENTS REQUIRED

NO. TOOLS REQUIRED DESCRIPTION PART NO. SERIAL NO. QTY REMARKS



PAGE 13 OF 9

HY R AULIC

j LUI


NO. MATERIAL REQUIRED DESCRIPTION PART NO. SERIAL NO. QTY REMARKS



PAGE 14 OF 9

HYk R AULIC

l LUI

k RESERVOIR SYSTEM No.1 and SYSTEM No.2

Hidraulic Fluid Reservoir System 1

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