PAGE 1 OF 9

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 the

Hydraulic 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 oil
which will flow from the disconnecting point.

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

Unscrew tubing (9, 10) and tubing (8) from the

hydraulic reservoir (5), using wrench 105-45051
W10.

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 the

washers (3)

Lift off hydraulic reservoir (1), together with bracket

(2) from the A1 alloy frame.

OVERHAUL INSPECTION WORKSHEET

HYDRAULIC FLUID RESERVOIR SYSTEM No.1 and SYSTEM No.2
 PAGE 2 OF 9
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 away

washers (3) and barcket (2).

Remove hollow screws (1,8, Fig.4, together with

sealing washers (2, 6) and banjo bolts (3, 7), and
the 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 the

hydraulic 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 collect
the oil which will flow from the disconnecting point

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

Screw the tubing (8, 9, 10) from hydraulic reservoir (5)

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

 PAGE 3 OF 9
NOTE:
Secure the hydraulic reservoir against tilting or falling down before you screw the last hex screw

Remove the hex screw (2, Fig.6) together with washers

(1) and hex nut (5)

Remove hex screws (3) with washer (4)

2.2 Dismantling of the hydraulic reservoir

Remove the wire locks

Screw out hex (3, Fig.7) and take away washers (4) and
bracket (2)

Remove double nipples (7, 8, Fig.8) with the sealing

rings (6, 9)

Remove hollow screw (5), banjo bolt (4), threaded

nipple (2) with the respective sealing rings (3, 1)

Discard the sealing rings (1, 3, 6, 9)

3 Disassembly of the System I/II hydraulic reservoir

The hydraulic reservoir may incorporate the following parts:

- Filter contamination indicator – Type THP (Fig. 9)
- Filter contamination indicator – Type FWM (Fig. 9)
NOT
- High pressure chamber seal – Type FWM (Fig. 15)
E
- High pressure chamber seal – Type THP (Fig. 16)
- Piston with expander spring
- Rislan – coated piston

3.1 Removal of the piston rod and the low-pressure piston.

Remove the wire locks of hex screws

Unscrew the hex screws (1) and take away washers (2)

Force cover (2, Fig. 11) from housing (5), using hex
screws (3)

Remove scrapes ring (1) from the bearing bore of cover

(2) and discard

Unscrew cap (6) from housing (5), using socket wrench

105-45051 W5

NOTE:
Applicable only to hydraulic reservoirs safetied with a tab washer

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

 PAGE 4 OF 9

Bend open tab washer (2, Fig.12)

Secure piston rod (3) at the lower piston and, using pin
spanner (105-45051 W3), and screw off sleeve (1)

Remove the tab washer (2) and discard

NOTE:
Applicable only to hydraulic reservoirs safetied with locking compound

Secure piston rod (3) at the lower piston and, using pin
spanner (105-45051 w3) and unscrew and remove
sleeve (1) after breaking the locking compound bond.
Remove residnal locking compound from the Threads
Remove residnal locking compound from the washer
(2).

NOTE:
Applicable to all types of hydraulic reservoir

Pull piston rod (3, Fig.13) downward from housing (2)

Remove O-ring (4) and back up ring (5) from piston rod
(3) an discard

Introduce disassembly tool (105-45051 W7) into bore

(6) in order to force piston (1) upwards

NOT Applicable only to piston with expander – spring

E
NOT Only discard expander spring (2, Fig.14) when damage
E

Take away the O-rings (1, 5), the Glid ring (3), the
expander spring (2) and the back up ring (4) and
discard

NOT Applicable only to Rilsan-coated piston

E

Remove and discard O-rings (1, 3, Fig. 14a) and back

up ring (2)

NOT Applicable to all types of hydraulic reservoir

E

Remove circlip (1, Fig.15)

Unscrew screw plug (3), using socket wrench (105-

45051 W2). Take away O-ring (5) and backup ring (4)
and discard

Take away O-rings (2, 7) from housing (6) and discard

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

 PAGE 5 OF 9

Remove back up ring (1, Fig.16) and O-rings (2, 4) from

housing (3) and discard

3.2 Removal of the low pressure safety valve (Fig.17)

NOT Compression spring (4) is preloaded
E

Screw plug (6) from housing (7)

Remove valve sleeve (2), washer (3) and compression

spring (4) from housing (7)

Take O-rings (1,5) from valve sleeve 92) and screw

plug (6) and discard

3.3 Removal of the filter with contamination indicator and non-return valve (Type “FWM”)

Remove locking wires

NOT The filter cover with tapped holes is forced off by means of screws. If there are no tapped holes, removal is by
E means of plastic wedges.

Remove the filter in the sequence shown in Fig. 18

Discard O-rings (5, 6)

Remove the contamination indicator and non-return

valve in the sequence shown in Fig.19

Discard O-rings (2, 11, 13, 15, 17, 20)

3.4 Removal of the filter with contamination indicator and non-return valve (Type “THP”)

Remove locking wires

NOT Force off the filter cover using screws

E

Remove the filter in the sequence shown in Fig.20

Discard O-rings (5, 6)

Remove the contamination indicator and non-return

valve in the sequence shown in Fig. 21

Discard O-rings (2) and back-up ring (8) if installed

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

 PAGE 6 OF 9

4 Inspection, Repair, or Replacement

NOT
The following parts must always be discarded and replaced by new parts
E

5. Reassembly of the System I/II reservoir

 All parts that have been reworked must again be cleaned in the ultrasonic bath before reassembly.
NOT  When installing O-rings, back up rings, Glyd rings and sealing rings, do not use tools with sharp edges
E or rough surfaces. Make sure that the O-rings fit evently and are not inverted. Wet the wear parts
mentioned above with hydraulic oil (item 110) before installing them.

5.1 Installation of the filter cover with filter, contamination indicator and “Type FWM” check valve

NOT
Install the O-ring for the control piston, using conical drift (105-45041 W15)
E

Install O-rings (1, Fig.24)

Carefully install control piston (5) in filter cover (6) and

make sure that the long shaft is to the right of stop pin
(14).

Install washer (7) and screw in plug (8).

Install compression spring (4) on control piston (5),

isntall wahser (3) on screw plug (2) and screw in the
plug (2).

Install stop pin (14) with compression spring (15) and

screw in plug (2)

Install stop pin (14) with compression spring (15) and

screw in plug (16).

 The matching washer (11) must be of such thickness that the stop screw, when tightened, is just below
NOT
the cylinder edge of the filter cover.
E
 The check valve is set during the test operations

Install the check valve in the correct sequence (9 to 13).

Install O-rings (4, Fig.25) on the filter cover (3).

NOT As the reservoir is going to be tested, a dummy filter (105-45051 W9) is installed instead of the filter element.
E

Carefully install filter cover (3) in the reservoir and

fasten with washers (2) and hex screws (1).

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

 PAGE 7 OF 9
NOT Locking wires will be attached after the test.
E
Installation of the filter with contamination indicator and
5.2
“Type THP” check valve.
NOT Setting of the check valve and isntallation of a matching washer (6) will follow during the tests.
E

Install the contamination indicator and check valce in

the correct sequence (Fig. 26)

NOT The locking wire will be attached after the test

E

Install O-rings (3, Fig. 27) on filter cover (4).

NOT As the reservoir is going to be tested, a dummy filter (105-45051 W9) is installed instead of the filter element.
E

Carefully install filter cover (4) in the reservoir and

fasten with washer (5) and hex screws (6)

NOT Locking wires will be attached after the test.

E
5.3 Installation of the low pressure safety valve (Fig. 28)

Install the low-pressure safety valve in the corrcet

sequence (Fig. 28)

NOT  Setting the low-pressure safety valve and matching of the washer (3) will be made during the tests.
E  The locking wire will be attached after the tests.
5.4 Installation of the low-pressure piston and piston rod.

Install O-ring (5, Fig. 29) and back O-ring (4) in screw
plug (3).

Install O-ring (2) on screw plug (3). Screw-in screw plug

(3) as far as it will go and lock with circlip (1).

Isntall O-ring (1, Fig. 30) and back up ring (2) in housing
(3).

NOT Applicable only to piston with expander-spring

E

Install O-ring (1, Fig. 31) in the psiton.

Insert expander spring (2) and Glyd ring (3) in the upper
piston groove.

Insert back-up ring (4) and O-ring 95) in the lower piston
groove.

NOT Applicable only to rislan-coated pistons.

E

Insert O-rings (1, 3 Fig. 13a) and back up ring (2) in

piston.

NOT Applicable to all types of hydraulic reservoir.

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

 PAGE 8 OF 9
E

Install O-ring (1, Fig. 32) and back up ring (2) as shown
in view A.

Do not tilt piston (4, Fig.33) when installing it in housing (5). (Damage to the sliding surfaces and sealing
NOTE
elements)

Install piston (4) in housing (5).

Degrease threads of piston rod (7) and sleeve (2) with

solvent (Item No. 201).

Insert piston rod (7) into housing (5) through bottom

opening and install washer (3).

Apply locking compound (Item 683) to threads of piston

rod (7) and sleeve (2), screw in sleeve (2) tightly.
(Use holding-up tool 105-45051W3 at the piston rod)

Install O-ring (6) in the threaded groove and screw on

cap (8).

CAUTION:
WHEN TIGHTENING THE RELIEF PLUGS (1), HOLD PISTON ROD (7) AT THE PRODRUDING HEX TO PREVENT IT
FROM BEING UNSCREWED IN THE PROCESS.

Tighten relief plug (1).

When the reservoir has been tested (Section 6), the protective cap (1, Fig. 34) with lock wire (2) is mounted.
NOTE
Fasten cover (4) with two screws initially.

Install scraper ring (3) in cover (4).

Put on cover (4) and fasten with two hex screws (6)
and washers (5).

5.5 Assembly of the connecting components.

1- System I (Fig.35)

Screw-in hollow screws (1, 8) with sealing ring

(2, 6) and banjo bolts (3, 7).

Screw-in double nipple (5) with sealing ring (4).

2- System II (Fig. 36)

Screw-in double nipples (7, 8) with sealing
rings (6, 9).

Screw-in hollow screw (5) with sealing ring (3)

HYDRAULIC FLUID RESERVOIR SYSTEM No.1 and SYSTEM No.2
 PAGE 9 OF 9
banjo bolts (4), screw nipple (2) and sealing
ring (1).
6 Testing the System I/II hydraulic fluid reservoir
NOTE When the required values or reactions cannot be obtained during the test, look up the reason in the table in
section 7 and remedy, if necessary.
6.1 Functional test of the “FWM” filter contamination indicator with bypass valve (Fig. 38)

Test Reequirements:
Dummy filter 105-45051 W9 has been installed; the hydraulic fluid reservoir is empty.

Apply a pressure of 2.0 bar to R.

Requirement; Control piston of filter contamination

indicator must not begin to extent.

Slowly increase pressure at R, up to 4.3 bar as a

maximum.

Requirement: control pirton of the filter contamination

indicator must begin to extent.

Increase pressure to 4.4 bar and reduce again.

Requirement; Control piston of filter contamination

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

WARNING:

THE STOP PIN WILL BLOCK THE CONTROL

PISTON. DO NOT FORCE IN THE CONTROL
PISTON.

Apply a pressure of 4.4 + 0.4 bar to “R” to 4.4 + 0.4

bar.

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

reservoir and comes out at port “S”.

Pull out filter cover (3, Fig. 4) after having removed the
hex screws (2) and washers (1).

Screw out the dummy filter (4) (105-45051 W9).

Screw filter element (5) with O ring (6) in the filter cover
by hand.

Check the position of the O rings (7, 8) in the ring

grooves of filter cover (3).

Install filter cover (3) in the housing and fasten with hex
screws (2) and washers (1).

Push in the indicator button (9) of the filter

HYDRAULIC FLUID RESERVOIR SYSTEM No.1 and SYSTEM No.2
 PAGE 10 OF 9
contamination indicator.

6.3 High-pressure test (Fig. 42)

Test requirements:
Cover removed

Close port in “S” with a pressure seal cap.

NOTE In order to fill the reservoir place it in such a position that filling point “R” is vertical.

Fill the reservoir with oil, close filling point “R” with a
pressure seal cap and repalce the reservoir in the
position shown in the drawing.

Apply a pressure of 103 bar at “Pv” and bleed the

system by means of the relief plug.

Apply a pressure of 103 bar four times to the system.

Requirement: NO oil must leak at the piston seal.

Apply a pressure of 155 bar for 5 minutes to the

system.

Requirement: No oil must leak at the piston seal

6.4 Test pressure on the return line (Fig. 43)

Close port “S” with a pressure seal cap.

NOTE: Bleed the reservoir well during the pressure
increase.

Slowly apply a pressure of 7.4 bar to return line “R” for

three times.

Requirement: Oil must not leak at port “Pv” and the

piston seal.

Apply a pressure of 7.4 bar to return line “R” for 10

minutes.

Requirement: No oil must leak at port “Pv” and at the

piston seal. Drop formation at the low pressure safety
valve (1, Fig. 43) is permissible.

6.5 Testing of the Low-Pressure Safety Valve (Fig.43)

Close port “S” with a pressure seal cap.

Gradually increase pressure at “R” port from zero to 7.5

bar and back to zero, 3 times.

(External leakage is not allowed. At “PV” and at low-

pressure safety valve, no leakage is allowed.)
HYDRAULIC FLUID RESERVOIR SYSTEM No.1 and SYSTEM No.2
 PAGE 11 OF 9

Increase pressure at “R” port to 8.5 bar

(Fluid must flow from low-pressure safety valve. Low-

Pressure safety valve is open).

Reduce pressure at “R” port to 7.5 bar.

(Leakage of only a few drops is allowed from low-

pressure safety valve. Low-pressure safety valve is
open).

Decrease pressure at “R” port to 5.4 bar.

(At the low-pressure safety valve, no leakage is

allowed.

6.6 Dynamic Leak Test at the Position (Fig. 44)

Attach cover and fix with two screws to prevent

contamination.

Connect ports “R” and “Pv” to test stand.

Close port “S” with a pressure seal cap.

Apply a pressure of 7 bar to “R”.

Reaction: The Piston travels downwards.

Reduce the pressure at “R” to a maximum of 1.8 bar

and increase the pressure at “Pv” 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 full psiton travels, there must not

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

6.7 Frictional Force Test between Piston and Housing (Fig. 45)

Close port “S” with a perssure seal cap.

Connect ports “Pv” and “R” to test stand.

Apply a constant pressure of 103 bar to “Pv”

HYDRAULIC FLUID RESERVOIR SYSTEM No.1 and SYSTEM No.2
 PAGE 12 OF 9

Requirement: piston (1) tarvel downwards.

Apply a pessure to “R” (approximately) 1.4-1.7 bar)

untill piston comes to a standstill.

Position dial indicator (1, Fig. 46) at the relief plug (3).

Increase pressure at “R” so that piston starts to move

upward, simultaneously measure the pressure at “R”.

Reduce pressure so thhat piston starts to move

downward, simultaneously measure the pressure.

Requirement: The differential pressure must not

exceed 0.4 bar.

6.8 Pressure test at the suction port

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

Close port “R” with a pressure seal cap.

Connect port “Pv” with the test stand.

Apply a pressure of 103 bar to “Pv”

Reaction: Pressure at the suction port “S” must be

beetwen 1.4 and 1.75 bar.

1.1 EQUIPMENTS REQUIRED

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

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

 PAGE 13 OF 9

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

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

 PAGE 14 OF 9

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