DESIGN 2 -TITE Nitrogen Gas Springs

READY THE INNOVATOR OF OUR INDUSTRY SM DESIGN 2 -TITE Nitrogen Gas Springs They truly are... Better by Design

DESIGN 2 -TITE - Expanded & Improved We are proud to offer our new and expanded line of nitrogen gas springs. Now the manufacturer of the world s finest die spring, SuperSpring, can supply you with the world s finest nitrogen gas spring, DESIGN 2 -TITE. Like SuperSpring, DESIGN 2 -TITE is completely engineered by us. We gave our engineers the following mission: 1. Simplify the design to improve performance and ease repair, 2. Design a more solid construction to extend life and increase safety, 3. Research and incorporate only the finest materials to offer the highest quality product on the market. We believe a better design produces a better product, and we are confident we have met our design goals. Try DESIGN 2 -TITE and experience for yourself the benefits of this superior line of nitrogen products. They truly are... Better by Design. NEW! The Performance Line RLP Series Greater initial force in a smaller diameter body. NEW! The Sub Compact Line RLSC Series Short stroke, high force in a compact body. IMPROVED! The ISO Line RL Series READY READY Now Offers Five Distinct Lines of Nitrogen Gas Springs NEW! The North American Line RLS Series Our proven ISO gas spring redesigned for the North American market. Our original gas spring now meets ISO and VDI requirements. NEW! The Micro Line RLM Series 2 All new, all rebuildable.

Index See What s New.. Our Gas Springs Now Come Assembled with SinterLube Take A Closer Look... Top Caps! Performance Gas Springs RLP-500... RLP-750, 1000... Sub Compact Gas Springs RLSC-1000... RLSC-1800, 4700... North American Gas Springs RLS-500,... RLS-750, 1500... 4 5 6 7 8 9 ISO Gas Springs RL-500... 10 RL-750, 1500... 11 RL-3000, 5000... 12 A Now Ready brings its revolutionary SinterLube technology to its complete line of nitrogen gas springs. Introducing the SinterLube Top Cap, exclusively from Ready, and with it, the world's only self-lubricating gas spring! This latest innovation to gas spring technology combines the strength of steel with the power of SinterLube to deliver more guide and better lubrication than any gas spring on the market today. SinterLube is a proprietary alloy material having good sliding lubricity and hardness which we have successfully used for years in the manufacture of guide bushings. We have now adapted this same technology to manufacture a new line of top caps for our full line of nitrogen gas springs. Here are the benefits: 1. Steel is a better material choice for top caps than bronze: steel is stronger, mates more easily with the steel body of the cylinder and is not prone to deforming during assembly or disassembly. 2. SinterLube is truly self-lubricating. After an initial application of lubricant which is done during assembly, the SinterLube Top Cap requires no additional lubrication during production and, provided the lubricant is not removed with solvent, no additional lubrication will be required for the life of the gas spring. This is a first for our industry and makes our gas springs unique. 3. Since SinterLube is self-lubricating, we've removed the oil groove from the prior design (see A above) providing up to 25% more guide and reducing the risk of gas pressure loss due to lateral forces during the operation of the die. Our new SinterLube Top Caps offer more guide than any of the competition we've tested. 4. There is virtually no wear of the SinterLube material, even in the toughest of applications, so the close tolerance geometry between our new SinterLube s Top Caps and the piston of the cylinder will be maintained even after millions of strokes. These benefits add up to less maintenance and a more reliable gas spring. Micro Gas Springs RLM-90... 13 RLM-180... 14 RLM-230... 16 RLM-300... 17 Clamping Options... 15 Pre-mounted Systems... 18 Assembling Fittings... 19 Control Panels... 20 Assembly Hose... 20 Fittings... 21 Junction Block... 22 Good Design... 23 Rebuild & Charge/Discharge. 24 Accessories... 26 Service Gauge Assembly... 26 Better by Design... 27 Try Design-Tite Nitrogen Gas Springs today and see for yourself how our superior design translates into the best gas spring available on the market! 3

RLP-500 READY The Performance Line (RLP Series) Every DESIGN 2 -TITE Performance gas spring provides greater force in a smaller body than the RLS and RL series gas springs. RLP-500 ø 20 mm (0.80) RLP gas springs are shipped charged at 150 bar (2175 psi). Stroke 2 mm (0.08) 9.5 mm (0.37) Better by Design... RLP gas springs are designed for easy service and safety Larger Diameter Piston Rod Provides Greater Force One piece construction Hollow piston rod lowers pressure rise Highly polished 2 mm (0.08) 3.5 mm (0.14) fill port M6 M x 61.0 Upper Clamping Groove For type C clamping SinterLube Top Cap Solid steel top cap with revolutionary SinterLube lining (see page 3). Designed with greater bearing area for improved support and guiding Threaded construction creates a mechanical solid for greater structural strength and safety Threaded Upper and Lower Body Construction Quickest to rebuild Easiest to maintain 4 mm (0.16) ø 20 mm (0.79) ø 33 mm (1.30) ø 38 mm (1.50) RLP-500 Stroke Lengths M M6 6 x (2) 1.0 (2) Inlet Valve Port Plug RLP-750 & 1000 Standard ISO charge port 37 JIC style Fill port for RLP-500 located on base Lower Clamping Groove ISO standard provides user flexibility RLP-500 Die Forces 473 dan (1063 lbs) 780 dan (1753 lbs) 4 Force is based on longest stroke. Force increase is less with shorter strokes. All dimensions and forces are nominal unless otherwise stated. Based on a charge pressure of 150 bar (2175 psi). Maximum available travel is 100% of stroke. Design should not exceed 90% of available stroke.

Here s How To Order The RLP: RLP-750 ø 25 mm (1.00) RLP-1000 x 25 Model Size Stroke Length in mm (refer to specific model page) RLP-1000 RLP-750, 1000 Stroke 2 mm (0.08) 13.5 mm (0.54) 2 mm (0.08) 3.5 mm (0.14) fill port G 1/8 G 1/8 x 28 11.5 mm (0.47) G 1/8 4 mm (0.16) ø 20 mm (0.79) ø 40 mm (1.60) ø 45 mm (1.80) M M8 8 x (2) 1.25 (2) M 8 (2) RLP-750 Stroke Lengths RLP-1000 Stroke Lengths RLP-1000 x 13 mm (0.51 inch) RLP-1000 x 25 mm (0.98 inch) RLP-1000 x 38 mm (1.50 inch) RLP-1000 x 50 mm (1.97 inch) RLP-1000 x 63 mm (2.48 inch) RLP-1000 x 80 mm (3.15 inch) 63 (2.48) 75 (2.95) 88 (3.47) 100 (3.94) 113 (4.45) 130 (5.12) 76 (2.99) 100 (3.94) 126 (4.96) 150 (5.91) 176 (6.93) 210 (8.27) RLP-750 Die Forces 739 dan (1661 lbs) 1350 dan (3033 lbs) RLP-1000 Die Force 994 dan (2236 lbs) 1930 dan (4337 lbs) Force is based on longest stroke. Force increase is less with shorter strokes. All dimensions and forces are nominal unless otherwise stated. Based on a charge pressure of 150 bar (2175 psi). Maximum available travel is 100% of stroke. Design should not exceed 90% of available stroke. 5

RLSC-1000 READY The Sub Compact Line (RLSC Series) Every DESIGN 2 -TITE Sub Compact gas spring combines the convenience of a self-contained gas spring with the increased on-contact force and shorter body height of a bore seal cylinder. RLSC-1000 RLSC gas springs are shipped charged at 150 bar (2175 psi). Better by Design... RLSC gas springs are designed for easy service and safety Piston Rod One piece construction Hollow piston rod lowers pressure rise Highly polished M 6 SinterLube Top Cap Solid steel top cap with revolutionary SinterLube lining (see page 3). Designed with greater bearing area for improved support and guiding Threaded construction creates a mechanical solid for greater structural strength and safety Threaded Upper and Lower Body Construction Quickest to rebuild Easiest to maintain RLSC-1000 Stroke Lengths M 6 (2) Highly Polished and Hardened Bore Extends seal life RLSC-1000 x 6 mm (0.24 inch) RLSC-1000 x 10 mm (0.39 inch) RLSC-1000 x 16 mm (0.63 inch) 55 (2.17) 68 (2.68) 84 (3.31) 61 (2.40) 78 (3.07) 100 (3.94) Inlet Valve RLSC-1000 x 25 mm (0.98 inch) 110 (4.33) 135 (5.32) Port Plug Standard ISO charge port RLSC-1000 x 32 mm (1.26 inch) RLSC-1000 x 40 mm (1.57 inch) 135 (5.31) 155 (6.10) 167 (6.57) 195 (7.68) RLSC-1000 x 50 mm (1.97 inch) 180 (7.09) 230 (9.05) RLSC-1000 Die Force 1063 dan (2389 lbs) 1590 dan (3572 lbs) 6 Force is based on longest stroke. Force increase is less with shorter strokes. All dimensions and forces are nominal unless otherwise stated. Based on a charge pressure of 150 bar (2175 psi). Maximum available travel is 100% of stroke. Design should not exceed 90% of available stroke.

Here s How To Order The RLSC: RLSC-1800 RLSC-4700 x 25 Model Size Stroke Length in mm (refer to specific model page) RLSC-4700 RLSC-1800, 4700 G 1/8 G 1/8 M 6 (2) M 8 (2) RLSC-1800 Stroke Lengths RLSC-4700 Stroke Lengths RLSC-1800 x 6 mm (0.24 inch) 60 (2.36) 66 (2.60) RLSC-4700 x 10 mm (0.39 inch) 70 (2.76) 80 (3.15) RLSC-1800 x 10 mm (0.39 inch) 70 (2.76) 80 (3.15) RLSC-4700 x 16 mm (0.63 inch) 90 (3.54) 106 (4.17) RLSC-1800 x 16 mm (0.63 inch) 90 (3.54) 106 (4.17) RLSC-4700 x 25 mm (0.98 inch) 110 (4.33) 135 (5.31) RLSC-1800 x 25 mm (0.98 inch) 110 (4.33) 135 (5.31) RLSC-4700 x 32 mm (1.26 inch) 135 (5.31) 167 (6.57) RLSC-1800 x 32 mm (1.26 inch) 130 (5.12) 162 (6.38) RLSC-4700 x 40 mm (1.57 inch) 160 (6.30) 200 (7.87) RLSC-1800 x 40 mm (1.57 inch) 150 (5.91) 190 (7.48) RLSC-4700 x 50 mm (1.97 inch) 190 (7.48) 240 (9.45) RLSC-1800 x 50 mm (1.97 inch) 170 (6.69) 220 (8.66) RLSC-1800 Die Force RLSC-4700 Die Force 1803 dan (4051 lbs) 3251 dan (7305 lbs) 4767 dan (10711 lbs) 7179 dan (16131 lbs) Force is based on longest stroke. Force increase in less with shorter strokes. All dimensions and forces are nominal unless otherwise stated. Based on a charge pressure of 150 bar (2175 psi). Maximum available travel is 100% of stroke. Design should not exceed 90% of available stroke. 7

RLS-500 READY The North American Line (RLS Series) Every DESIGN 2 -TITE North American gas spring meets all ISO and VDI piston rod and body diameter standards, in addition to mounting and charge port specifications and features the shorter body height common in North America. RLS gas springs are shipped charged at 150 bar (2175 psi). RLS-500 Stroke 2 mm (0.08) ø 20 mm (0.80) 13.5 mm (0.54) Better by Design... RLS and RL gas springs are designed for easy service and safety 2 mm (0.08) Piston Rod One piece construction Hollow piston rod lowers pressure rise Highly polished 3.5 mm (0.14) fill port G 1/8 G 1/8 x 28 11.5 mm (0.47) Upper Clamping Groove For type C clamping SinterLube Top Cap Solid steel top cap with revolutionary SinterLube lining (see page 3). Designed with greater bearing area for improved support and guiding Threaded construction creates a mechanical solid for greater structural strength and safety 4 mm (0.16) ø 20 mm (0.79) ø 40 mm (1.60) ø 45 mm (1.80) RLS-500 Stroke Lengths M M8 8 x (2) 1.25 (2) Threaded Upper and Lower Body Construction Quickest to rebuild Easiest to maintain RLS-500 x 13 mm (0.51 inch) RLS-500 x 25 mm (0.98 inch) RLS-500 x 38 mm (1.50 inch) 63 (2.48) 75 (2.95) 88 (3.47) 76 (2.99) 100 (3.94) 126 (4.96) Inlet Valve RLS-500 x 50 mm (1.97 inch) 100 (3.94) 150 (5.91) Port Plug Standard ISO charge port 37 JIC style RLS-500 x 63 mm (2.48 inch) RLS-500 x 80 mm (3.15 inch) 113 (4.45) 130 (5.12) 176 (6.93) 210 (8.27) Lower Clamping Groove ISO standard provides user flexibility RLS-500 Die Force 473 dan (1063 lbs) 681 dan (1530 lbs) 8 Force is based on longest stroke. Force increase is less with shorter strokes. All dimensions and forces are nominal unless otherwise stated. Based on a charge pressure of 150 bar (2175 psi). Maximum available travel is 100% of stroke. Design should not exceed 90% of available stroke.

Here s How To Order The RLS: RLS-1500 x 25 Model Size Stroke Length in mm (refer to specific model page) RLS-750, 1500 RLS-750 ø 25 mm (0.98) RLS-1500 ø 36 mm (1.42) Stroke 32 mm (0.12) (0.08) 12.5 mm (0.49) Stroke 3 mm (0.12) 15.5 mm (0.61) 4 mm (0.16) 5 mm (0.20) 7 mm (0.28) fill port G 1/8 G 1/8 x 28 11.5 mm (0.47) 7 mm (0.28) fill port G 1/8 G 1/8x 28 11.5 mm (0.47) 8 mm (0.32) ø 20 mm (0.79) ø 43 mm (1.69) ø 50 mm (1.97) M M8 8 x (2) 1.25 (2) 8 mm M M8 8 x (4) 1.25 (4) (0.32) ø 40 mm ( 1.60) ø 67 mm (2.64) ø 75 mm (2.95) RLS-750 Stroke Lengths RLS-1500 Stroke Lengths RLS-750 x 13 mm (0.51 inch) 63 (2.48) 76 (2.99) RLS-1500 x 25 mm (0.98 inch) 126.6 (4.98) 151.6 (5.97) RLS-750 x 25 mm (0.98 inch) 75 (2.96) 100 (3.94) RLS-1500 x 38 mm (1.50 inch) 139 (5.47) 177 (6.97) RLS-750 x 38 mm (1.50 inch) 88 (3.46) 126 (4.99) RLS-1500 x 50 mm (1.97 inch) 151.6 (5.97) 201.6 (7.94) RLS-750 x 50 mm (1.97 inch) 100 (3.94) 150 (5.91) RLS-1500 x 63 mm (2.48 inch) 164 (6.46) 227 (8.94) RLS-750 x 63 mm (2.48 inch) 113 (4.45) 176 (6.93) RLS-1500 x 80 mm (3.15 inch) 181.6 (7.15) 261.6 (10.30) RLS-750 x 80 mm (3.15 inch) 130 (5.12) 210 (8.27) RLS-1500 x 100 mm (3.94 inch) 201.6 (7.94) 301.6 (11.87) RLS-750 x 100 mm (3.94 inch) 150 (5.90) 250 (9.84) RLS-1500 x 125 mm (4.92 inch) 226.6 (8.92) 351.6 (13.84) RLS-750 Die Force 739 dan (1661 lbs) 1180 dan (2651 lbs) RLS-1500 Die Force 1532 dan (3442 lbs) 2240 dan (5033 lbs) Force is based on longest stroke. Force increase is less with shorter strokes. All dimensions and forces are nominal unless otherwise stated. Based on a charge pressure of 150 bar (2175 psi). Maximum available travel is 100% of stroke. Design should not exceed 90% of available stroke. 9

RL-500 READY The ISO Line (RL Series) Every DESIGN 2 -TITE ISO gas spring meets all ISO and VDI piston rod, body and height standards, in addition to mounting and charge port specifications. RL gas springs are shipped charged at 150 bar (2175 psi). RL-500 Stroke 2 mm (0.08) ø 20 mm (0.80) 13.5 mm (0.54) 2 mm (0.08) Better by Design... RLS gas springs are designed for easy service and safety Piston Rod One piece construction Hollow piston rod lowers pressure rise Highly polished 3.5 mm (0.14) fill port G 1/8 G 1/8x 28 11.5 mm (0.47) Upper Clamping Groove For type C clamping SinterLube Top Cap Solid steel top cap with revolutionary SinterLube lining (see page 3). Designed with greater bearing area for improved support and guiding Threaded construction creates a mechanical solid for greater structural strength and safety Threaded Upper and Lower Body Construction Quickest to rebuild Easiest to maintain Inlet Valve Port Plug Standard ISO charge port 37 JIC style 4 mm (0.16) RL-500 x RL-500 x RL-500 x RL-500 Die Force ø 20 mm (0.79) ø 40 mm (1.60) ø 45 mm (1.80) RL-500 Stroke Lengths 25 mm (0.98 inch) 50 mm (1.97 inch) 80 mm (3.15 inch) M M8 8 x (2) 1.25 (2) 110 (4.33) 135 (5.31) 165 (6.50) 473 dan (1063 lbs) 623 dan (1400 lbs) ed 135 (5.31) 185 (7.28) 245 (9.65) Lower Clamping Groove ISO standard provides user flexibility 10 Force is based on longest stroke. Force increase is less with shorter strokes. All dimensions and forces are nominal unless otherwise stated. Based on a charge pressure of 150 bar (2175 psi). Maximum available travel is 100% of stroke. Design should not exceed 90% of available stroke.

Here s How To Order An RL: RL 3000 x 80 Model Size Stroke Length in mm (refer to specific model page) RL-750, 1500 RL-750 ø 25 mm (0.98) RL-1500 ø 36 mm (1.42) Stroke 3 mm (0.12) 12.5 mm (0.49) Stroke 3 mm (0.12) 15.5 mm (0.61) 4 mm (0.16) 5 mm (0.20) 7 mm (0.28) fill port fill port G 1/8 G 1/8x 28 G 1/8 G 1/8 x 28 7 mm 11.5 mm (0.28) (0.47) 11.5 mm (0.47) 8 mm (0.32) ø 20 mm (0.79) ø 43 mm (1.69) ø 50 mm (1.97) M M8 8 x (2) 1.25 (2) 8 mm M8 M 8 x 1.25 (4) (4) (0.32) ø 40 mm (1.60) ø 67 mm (2.64) ø 75 mm (2.95) RL-750 Stroke Lengths RL-1500 Stroke Lengths RL-750 x 25 mm (0.98 inch) 120 (4.72) 145 (5.70) RL-1500 x 25 mm (0.98 inch) 135 (5.31) 160 (6.30) RL-750 x 38 mm (1.50 inch) 133 (5.24) 171 (6.73) RL-1500 x 38 mm (1.50 inch) 148 (5.83) 186 (7.32) RL-750 x 50 mm (1.97 inch) 145 (5.70) 195 (7.68) RL-1500 x 50 mm (1.97 inch) 160 (6.30) 210 (8.27) RL-750 x 63 mm (2.48 inch) 158 (6.22) 221 (8.70) RL-1500 x 63 mm (2.50 inch) 173 (6.81) 236 (9.29) RL-750 x 80 mm (3.15 inch) 175 (6.89) 255 (10.04) RL-1500 x 80 mm (3.15 inch) 190 (7.48) 270 (10.63) RL-750 x 100 mm (3.94 inch) 195 (7.68) 295 (11.61) RL-1500 x 100 mm (3.94 inch) 210 (8.27) 310 (12.20) RL-750 x 125 mm (4.92 inch) 220 (8.66) 345 (13.58) RL-1500 x 125 mm (4.92 inch) 235 (9.25) 360 (14.71) RL-750 x 160 mm (6.30 inch) 255 (10.04) 415 (16.34) RL-1500 x 160 mm (6.30 inch) 270 (10.63) 430 (16.93) RL-750 Die Force 739 dan (1661 lbs) 1059 dan (2372 lbs) RL-1500 Die Force 1532 dan (3442 lbs) 2142 dan (4813 lbs) Force is based on longest stroke. Force increase is less with shorter strokes. All dimensions and forces are nominal unless otherwise stated. Based on a charge pressure of 150 bar (2175 psi). Maximum available travel is 100% of stroke. Design should not exceed 90% of available stroke. 11

RL-3000, 5000 READY RL-3000 ø 50 mm (1.97) RL-5000 ø 65 mm (2.56) Stroke 3 mm (0.12) 18.5 mm (0.73) Stroke 3 mm (0.12) 20 mm (0.79) 5 mm (0.20) 5 mm (0.20) 7 mm (0.28) fill port fill port G 1/8 G 1/8x 28 11.5 mm G 1/8 G 1/8 x 28 (0.47) 7 mm (0.28) 11.5 mm (0.46) 8 mm (0.32) ø 60 mm (2.36) ø 87 mm (3.43) ø 95 mm (3.74) M8 M 8 x 1.25 (4) (4) 8 mm M M10 x (4) 1.50 (4) (0.32) ø 80 mm (3.15) ø 112 mm (4.41) ø 120 mm (4.72) RL-3000 Stroke Lengths RL-5000 Stroke Lengths RL-3000 x 25 mm (0.98 inch) 145 (5.71) 170 (6.69) RL-5000 x 25 mm (0.98 inch) 165 (6.50) 190 (7.48) RL-3000 x 38 mm (1.50 inch) 158 (6.22) 196 (7.72) RL-5000 x 38 mm (1.50 inch) 178 (7.01) 216 (8.50) RL-3000 x 50 mm (1.97 inch) 170 (6.69) 220 (8.66) RL-5000 x 50 mm (1.97 inch) 190 (7.48) 240 (9.45) RL-3000 x 63 mm (2.50 inch) 183 (7.20) 246 (9.69) RL-5000 x 63 mm (2.50 inch) 203 (7.99) 266 (10.47) RL-3000 x 80 mm (3.15 inch) 200 (7.87) 280 (11.02) RL-5000 x 80 mm (3.15 inch) 220 (8.66) 300 (11.81) RL-3000 x 100 mm (3.94 inch) 220 (8.66) 320 (12.60) RL-5000 x 100 mm (3.94 inch) 240 (9.45) 340 (13.39) RL-3000 x 125 mm (4.92 inch) 245 (9.65) 370 (14.57) RL-5000 x 125 mm (4.92 inch) 265 (10.43) 390 (15.35) RL-3000 x 160 mm (6.30 inch) 280 (11.02) 440 (17.32) RL-5000 x 160 mm (6.30 inch) 300 (11.81) 460 (18.11) RL-3000 Die Force 2955 dan (6640 lbs) 4289 dan (9637 lbs) RL-5000 Die Force 4994 dan (11222 lbs) 7296 dan (16394 lbs) 12 Force is based on longest stroke. Force increase is less with shorter strokes. All dimensions and forces are nominal unless otherwise stated. Based on a charge pressure of 150 bar (2175 psi). Maximum available travel is 100% of stroke. Design should not exceed 90% of available stroke.

RLM-90 The Micro Line (RLM Series) Every DESIGN 2 -TITE Micro 90 and 180 gas spring is adjustable, rechargeable and rebuildable. RLM-90 ø 8 (0.31) All RLM Series Gas Springs meet all ISO piston rod, body and height standards, in addition to mounting specifications. RLM-90 and 180 gas springs are shipped at full charge unless otherwise specified. Stroke 1mm (0.04) 17 mm (0.67) See adjacent page for ordering information. Better by Design... RLM gas springs are designed for easy service and safety fill port M6 M x 61.0 groove radius 1 mm (0.04) colored ring indicates force Piston Rod One piece construction Highly polished ø 19 mm (0.75) 6 mm (0.24) Solid Bronze Top Cap Threaded bronze top cap construction creates a mechanical solid for greater strength and safety. Bronze top cap and bearing provide greater bearing area for improved support and guiding. RLM-90 Stroke Lengths RLM-90 x 15 mm (0.59 inch) RLM-90 x 25 mm (0.98 inch) RLM-90 x 38 mm (1.50 inch) 57 (2.24) 67 (2.64) 80 (3.15) 72 (2.83) 92 (3.62) 118 (4.65) Upper Groove Threaded Upper and Lower Body Construction Quickest to rebuild Easiest to maintain Inlet Valve, Fill Port RLM-90 x 50 mm (1.97 inch) RLM-90 x 63 mm (2.50 inch) RLM-90 x 80 mm (3.15 inch) RLM-90 Force Chart DIE OPEN FORCE DaN lbs 134 111 89 67 45 22 0 92 (3.62) 108.5 (4.27) 125 (4.92) 300 250 200 150 100 50 0 134 111 89 67 45 22 0 0 20 40 80 100 TRAVEL (% of stroke) yellow red blue green DIE CLOSED FORCE DaN lbs 142 (5.59) 172 (6.77) 205 (8.07) 300 250 200 150 100 50 0 Die closed force is based on longest stroke. Force increase is less with shorter stroke. All dimensions and forces are nominal unless otherwise stated. Maximum available travel is 100% of stroke. Design should not exceed 90% of available stroke. 13

RLM-180, Mounting Styles Here s How to Order the RLM-90 and 180: RLM-180 x 25 - Model Size Stroke Length in mm YELLOW Force by Colour (yellow, red, blue, green) RLM-180 ø 12 (0.47) Contact Forces - RLM-90, 180 CONTACT FORCE Yellow Red Blue Green Stroke 1mm (0.04) 17 mm (0.67) groove radius 1 mm (0.04) RLM-90 x RLM-180 x die contact force charged pressure die contact force charged pressure dan lbs bar psi dan lbs bar psi 87.5 197 175 2538 200 450 177 2567 75 169 150 2175 150 337 133 1922 50 112 100 1450 100 225 89 1284 25 56 50 725 50 112 44 639 fill port M6 M x 61.0 colored ring indicates force Mounting Styles - RLM-90, 180 7 mm (0.28) Shown are examples of some typical mounting configurations for the Micro line - designed to be interchangeable with standard micro gas spring mountings. ø 25 mm (0.98) RLM-180 Stroke Lengths RLM-180 x 15 mm (0.59 inch) 57 (2.24) 72 (2.83) Type A Type B Type C Type D RLM-180 x 25 mm (0.98 inch) 67 (2.64) 92 (3.62) RLM-180 x 38 mm (1.50 inch) 80 (3.15) 118 (4.65) Clamping Options - RLM-90, 180 RLM-180 x 50 mm (1.97 inch) RLM-180 x 63 mm (2.50 inch) RLM-180 x 80 mm (3.15 inch) RLM-180 x 100 mm (3.94 inch) RLM-180 x 125 mm (4.92 inch) 92 (3.62) 108.5 (4.27) 125 (4.92) 145 (5.71) 170 (6.69) 142 (5.59) 172 (6.77) 205 (8.07) 245 (9.65) 295 (11.61) 45 mm 1.77 in. 32 mm 1.26 in. 25 mm 0.98 in. 7 mm 0.275 in. RLM 90 14 RLM-180 Force Chart DIE OPEN FORCE DaN lbs 311 267 222 178 134 89 45 0 700 600 500 400 300 200 100 0 0 20 40 80 100 311 267 222 178 134 89 45 0 TRAVEL (% of stroke) yellow red blue green DIE CLOSED FORCE DaN lbs 700 600 500 400 300 200 100 0 30 mm 1.18 in. 50 mm 1.97 in. RLM 180 34 mm 1.34 in. 9 mm 0.354 in. Die closed force is based on longest stroke. Force increase is less with shorter stroke. All dimensions and forces are nominal unless otherwise stated. Maximum available travel is 100% of stroke. Design should not exceed 90% of available stroke.

Base Mount Style Clamping Options MODEL A B T D BC RLx-300 (1000) 70 (2.76) 50 (1.97) 20 (.79) 9 (.35) NA A RLx-500 70 (2.76) 50 (1.97) 20 (.79) 9 (.35) NA D RLx-750 (1800) 75 (2.95) 56.5 (2.22) 20 (.79) 9 (.35) NA RLx-1500 (4700) 100 (3.94) 73.5 (2.89) 40 (1.57) 11 (.433) NA B T RLx-3000 120 (4.72) 92 (3.62) 60 (2.36) 13.5 (.531) NA RLx-5000 140 (5.51) 109.5 (4.31) 80 (3.15) 13.5 (.531) NA Two-Part Style A B T D BC A RLx-300 55 (2.17) 40 (1.57) 7 (.275) 7 (.275) 56.5 (2.22) RLx-500 RLx-750 RLx-1500 70 (2.76) 75 (2.95) 100 (3.94) 50 (1.97) 56.4 (2.22) 73.5 (2.89) 12 (.47) 12 (.47) 12 (.47) 9 (.35) 9 (.35) 11 (.433) 70.7 (2.78) 80 (3.15) 104 (4.09) B T D RLx-3000 120 (4.72) 92 (3.62) 12 (.47) 13 (.512) 130 (5.12) RLx-5000 140 (5.51) 109.5 (4.31) 12 (.47) 13 (.512) 155 (6.10) Round Style A B T D BC A RLx-300 68 (2.68) 40 (1.57) 9 (.354) 7 (.275) 56.5 (2.22) RLx-500 RLx-750 86 (3.39) 95 (3.74) 50 (1.97) 56.5 (2.22) 9 (.354) 9 (.354) 13 (.51) 13 (.51) 70.7 (2.78) 80 (3.15) B T D RLx-1500 122 (4.80) 73.5 (2.89) 9 (.354) 13 (.51) 104 (4.09) RLx-3000 150 (5.91) 92 (3.62) 9 (.354) 13 (.51) 130 (5.12) RLx-5000 175 (6.89) 109.5 (4.31) 13 (.51) 21 (.83) 155 (6.10) Lug Mount (2 lug/special) A B T D BC A RLx-300 NA NA NA NA NA RLx-500 95.8 (3.77) 25 (.98) 7 (.28) 9 (.35) 70.7 (2.78) D RLx-750 110 (4.33) 30 (1.18) 14.5 (.57) 13 (.51) 80 (3.15) B T RLx-1500 134 (5.27) 30 (1.18) 14.5 (.57) 13 (.51) 104 (4.09) RLx-3000 170 (6.69) 40 (1.57) 14.5 (.57) 17 (.67) 130 (5.12) RLx-5000 205 (8.07) 50 (1.97) 14.5 (.57) 17 (.67) 155 (6.10) Square Style A RLx-300 A B T D BC 68 (2.68) 40 (1.57) 9 (.354) 7 (.275) 56.5 (2.22) D RLx-500 RLx-750 86 (3.39) 95 (3.74) 50 (1.97) 56.5 (2.22) 9 (.354) 9 (.354) 13 (.51) 13 (.51) 70.7 (2.78) 80 (3.15) B T RLx-1500 122 (4.80) 73.5 (2.89) 9 (.354) 13 (.51) 104 (4.09) RLx-3000 150 (5.91) 92 (3.62) 9 (.354) 13 (.51) 130 (5.12) RLx-5000 175 (6.89) 109.5 (4.31) 13 (.51) 21 (.83) 155 (6.10) 15

RLM-230 READY The Micro Line (RLM Series) Every DESIGN 2 -TITE Micro 230 and 300 gas spring is adjustable, rechargeable and rebuildable. RLM-230 ø 14 (0.55) All RLM Series Gas Springs meet all ISO piston rod, body and height standards, in addition to mounting specifications. RLM-230 and 300 gas springs are shipped charged at 150 bar (2175 psi). Stroke 1mm (0.04) 17 mm (0.67) Better by Design... The RLM-230 is designed for easy service and safety Piston Rod One piece construction Hollow piston rod lowers pressure rise Highly polished fill port M6 M x 61.0 groove radius 1 mm (0.04) Solid Bronze Top Cap Threaded bronze top cap construction creates a mechanical solid for greater strength and safety. Bronze top cap and bearing provide greater bearing area for improved support and guiding. Upper Clamping Groove For Type C Clamping Threaded Upper and Lower Body Construction Quickest to Rebuild Easiest to Maintain RLM-230 x 10 mm (0.39 inch) RLM-230 x 15 mm (0.59 inch) RLM-230 x 25 mm (.98 inch) RLM-230 x 38 mm (1.50 inch) ø 17 (0.67) ø 32mm (1.26) RLM-230 Stroke Lengths 60 (2.36) 65 (2.56) 75 (2.95) 88 (3.47) M M6 6 x (2) 1.0 (2) 70 (2.76) 80 (3.15) 100 (3.94) 126 (4.97) Inlet Valve, Fill Port RLM-230 x 50 mm (1.97 inch) 100 (3.94) 150 (5.91) Here s How To Order the RLM-230: RLM-230 x 25 Model Size Stroke Length in mm RLM-230 x 63 mm (2.48 inch) RLM-230 x 80 mm (3.15 inch) RLM-230 x 100 mm (3.94 inch) RLM-230 x 125 mm (4.92 inch) RLM-230 Die Force 113 (4.45) 130 (5.12) 150 (5.91) 175 (6.89) 232 dan (521 lbs) 303.2 dan (681 lbs) 176 (6.93) 210 (8.27) 250 (9.84) 300 (11.81) 16 Force is based on longest stroke. Force increase is less with shorter strokes. All dimensions and forces are nominal unless otherwise stated. Based on a charge pressure of 150 bar (2175 psi). Maximum available travel is 100% of stroke. Design should not exceed 90% of available stroke.

READY RLM-300 RLM-300 Better by Design... The RLM-300 is designed for easy service and safety Piston Rod One piece construction Hollow piston rod lowers pressure rise Highly polished M 6 Solid Bronze Top Cap Threaded bronze top cap construction creates a mechanical solid for greater strength and safety. Bronze top cap and bearing provide greater bearing area for improved support and guiding. M 6 (2) Upper Clamping Groove For Type C Clamping Threaded Upper and Lower Body Construction Quickest to Rebuild Easiest to Maintain RLM-300 Stroke Lengths Lower Clamping Groove ISO Standard Provides User Flexibility RLM-300 x 10 mm (0.39 inch) 60 (2.36) 70 (2.76) Inlet Valve, Fill Port RLM-300 x 13 mm (0.51 inch) 63 (2.48) 76 (2.99) RLM-300 x 16 mm (0.63 inch) 66 (2.60) 82 (3.23) RLM-300 Die Force RLM-300 x 25 mm (0.98 inch) RLM-300 x 38 mm (1.50 inch) 75 (2.95) 88 (3.47) 100 (3.94) 126 (4.96) 267 dan (598 lbs) 336.4 dan (756 lbs) RLM-300 x 50 mm (1.97 inch) 100 (3.94) 150 (5.91) RLM-300 x 63 mm (2.48 inch) RLM-300 x 80 mm (3.15 inch) 113 (4.45) 130 (5.12) 176 (6.93) 210 (8.27) Here s How to Order the RLM-300: RLM-300 x 100 mm (3.94 inch) 150 (5.91) 250 (9.84) RLM-300 x 25 RLM-300 x 125 mm (4.92 inch) 175 (6.89) 300 (11.81) Model Size Stroke Length in mm Force is based on longest stroke. Force increase is less with shorter strokes. All dimensions and forces are nominal unless otherwise stated. Based on a charge pressure of 150 bar (2175 psi). Maximum available travel is 100% of stroke. Design should not exceed 90% of available stroke. 17

Premounted Systems Operating Conditions READY Pre-mounted Systems How To Order a Pre-mounted System: When specifying a pre-mounted system the following information is necessary to ensure proper application and fit: 1. The finished plate length, width, and plate thickness including specific tolerances. 2. The location, size and stroke, preferred mounting, and quantity of each DESIGN 2 -TITE gas spring. 3. The location of the control panel in relation to the plate. If remote mounting is desired, please specify hose length. 4. Provide a plan drawing for nitrogen hose routings. The plan drawing must include the hose routing to ensure proper fit in your application. 5. The size and exact location of all plate mounting holes must be specified. If counterbored holes are required, please detail. An affordable and flexible alternative to nitrogen manifold systems. All pre-mounted systems are assembled and supplied ready for installation in your die. All gas springs are pre-mounted, pre-hosed and pressure tested prior to shipping, saving both time and money. All RLS, RL, and RLP-750 & 1000 gas springs can be made part of a pre-mounted system. Gas Spring General Operating Conditions Pressure Medium:........................ Nitrogen Gas Maximum Charged Pressure: 150 bar (2175 psi)... RLP, RLSC, RLS, RL and RLM Micro 230 & 300 180 bar (2610 psi)... RLM Micro 90 &180 Minimum Charged Pressure: 50 bar (725 psi)..... RLP, RLSC, RLS, RL and RLM Micro Gas Springs Maximum Operating Temperature:............ +80C (+176 F) Maximum Piston Rod Velocity:............... cs/min (continuous strokes per minute) models 90, 180, 230-125 cs/min: 300, 500-95 cs/min models 750, 1000, 1500, 1800-75 cs/min: 3000, 4700, 5000-55 cs/min Maximum Utilized Stroke:.................. 100% of the stroke (Design should not exceed 90%) Maximum Rod Misalignment:................ 0.15 18

READY Assembling Fittings Assembling Fittings to Gas Springs Our 37 JIC flared fittings are stocked items. For use with all RLS, RL, and RLP-750, 1000 gas springs. Torque Specifications: Nm Lbf/ft 37 JIC 16 12 Fitting Type: Hose swivel BSPP Male 45 BSPP Elbow 90 Branch tee swivel nut Run tee swivel nut Straight fitting Charge port plug 37 JIC READY Part # RT10655-4-4 RT4V40MX-S RT4C40MX-S RT4S6X-S RT4R6X-S RT4F4OMX-S H2-XXXXX-XXX-13 slot style Important Steps When Hosing Gas Springs Together 1. Always discharge all nitrogen pressure before working on any gas spring. Follow service instructions. 2. Using a slot screw driver, slowly remove port plug found on base of spring. A small amount of gas pressure may be present behind installed plug and an audible wisp of gas may be heard. 3. Discharge all nitrogen pressure and then remove nitrogen inlet valve located within port. It is helpful to remove the valve while the gas spring is in an upside down or rod down position. This will keep the lubricating oil from oozing out of the spring. Metric socket cap port plug available upon request. Port Plug Inlet Valve steps 2 & 3 4. Install the appropriate straight or angle fitting, using a 14 mm (9/16 ) open-end wrench. Please take care not to over-torque the fitting (refer to torque specification chart). 5. Attach the hose swivel nut fitting. We recommend that you wait to fully torque all fittings until the hose is in proper position. NOTE: For best results, minimize the number of fittings used in the system. Use only approved hose and fittings. Hose and Swivel Straight Fitting 90 Swivel Nut Fitting 37 JIC fittings pictured steps 4, 5 & 6 All dimensions and forces are nominal unless otherwise stated. 19

Control Panel, Assembly Hose Control Panel READY Fitting NP1000-3 MODEL KA 110-01-250 It can be used when filled with gas to monitor the pressure. Each control console has a built in safety plug. Front View Side View Bottom View 1. Safety Plug 2. Inlet Valve 3. Exhaust Valve 4. Pressure Guage Assembly Hose Important: The hose length should be a minimum of 5% longer than the actual measured length. The additional length provides for the contraction of the hose length when pressurized. Note: The inlet valve must be removed prior to hosing. 37 JIC Hose Part # RT520410655-(* (*) = specify required hose length) Part No. Hose I.D. Hose O.D. Max. Operating Pressure MPa Burst Pressure MPa Min. Bend Radius Thread Size A H Hex W Hex B 37 JIC mm RT520410655 inch 6.4.26 13.50 51 345 1380 2 9/16-18 50 2 18.71 16.63 27 1 20 All dimensions and forces are nominal unless otherwise stated.

O-Ring Face Seal Fittings BSPP Male Straight Connector BSPP Male 45 Elbow 26.0 16.0 10.0 14 4.5 4.5 4.5 9/16-18 27.5 19.0 14 G-1/8 9/16-18 G-1/8 17 4.5 Part # RT42F4OMLO-S Part # RT42V4OMLOS-S 30.0 BSPP Male 90 Elbow 14 22.0 21.5 Part # RT42C4OMLO-S O-Ring and 37 Fittings 4.5 G-1/8 4.5 9/16-18 14 90 Swivel Nut Elbow Swivel Nut Run Tee Swivel Nut Branch Tee 14 26.5 9/16-18 21.5 26.5 9/16-18 21.5 9/16-18 5.0 21.5 5.0 17 9/16-18 4.0 14 5.0 17 9/16-18 4.0 26.5 4.0 17 14 Part # RT4C6MLO-S Part # RT4R6MLO-S Part # RT4S6MLO-S 37 JIC Fittings BSPP Male Straight Connector BSPP Male 45 Elbow BSPP Male 90 Elbow 28.7 18.3 11 22.6 6.3 G-1/8 16 14.0 7/16-20 G-1/8 Male Straight Connector Part # RT4F40MX-S 26.5 11 6.3 Part # RT4V40MX-S 7/16-20 G-1/8 14 26 6.3 7/16-20 14 Part # RT4C40MX-S G-1/8 90 Swivel Nut Elbow Swivel Nut Run Tee Swivel Nut Branch Tee 7/16 16.8 22.6 4.4 7/16-20 7/16 25.4 16.8 4.4 7/16-20 7/16 16.8 22.6 4.4 25.4 7/16-20 4.4 7/16-20 9/16 22.6 4.4 7/16-20 9/16 7/16-20 25.4 7/16-20 4.4 7/16-20 9/16 Part # RT4C6X-S Part # RT4R6X-S Part # RT4S6X-S All dimensions and forces are nominal unless otherwise stated. 21

Junction Block, General Notes READY Junction Block HR-6 Model shown (4) holes drilled and counterbored to accommodate M10 or 3/8 socket head cap screws. G-1/8 BSPP inlet port supplied with 37 JIC straight fitting. Rupture plug 350 bar (5,000 psi) G-1/8 BSPP outlet port supplied with fitting and/or plugs. Available in 2, 4 or 6 ports. 37 JIC fittings pictured Model A B C D E F G H I J HR-2 mm inch 38 1.50 9 0.35 22 0.87 29 1.14 73 2.87 9 0.35 55 2.17 25 0.98 36.5 1.44 22 0.87 HR-4 mm inch 38 1.50 9 0.35 22 0.87 29 1.14 131 5.16 37 1.46 57 2.24 25 0.98 65.5 2.58 22 0.87 HR-6 mm inch 38 1.50 9 0.35 22 0.87 29 1.14 187 7.36 37 1.46 114 4.49 25 0.98 93.5 3.68 22 0.87 General Notes We recommend that all gas springs are supported on the base at all times. No stock removal permitted from any surface of the gas springs. All hoses and fittings are available individually, as assemblies, or in bulk upon request. We reserve the right to change the design, specifications, dimensions, force and offering without notice. All dimensions and forces are nominal unless otherwise stated. Measurement Converter For conversion of metric and US measurements, use these conversion factors; Length: 1 inch = 25.4 millimeters 1 millimeter = 0.03937 inches Pressure Ratings: PSI to BAR = PSI x 0.06894757 = BAR Volume: 1 cubic inch = 16378.06 cubic millimeters 1 cubic millimeter = 0.000061023 cubic inches Liquid Capacities: 1 milliliter = 0.03381 fluid ounces Weight: 1 pound = 0.4535924 kilograms 1 ton = 907.1847 kilograms 1 kilogram = 2.204622 pounds 1 metric ton = 2204.622 pounds 1 metric ton = 1.1023114 tons Area: 1 square inch = 645.16 square millimeters 22

READY Design Guide Good Performance Begins With Good Design Self-Contained: When placed in a die pocket, gas springs should always be secured with bolts. Unlike pre-loaded die springs, gas springs operate at less than maximum efficiency when inserted into a pocket, in either an upper or lower application. This is true because the clearance fit between the gas spring and the pocket provides space for the gas spring to move off center as the press cycles. Over time, this can damage the gas spring and ultimately shorten its life. By securing a gas spring with bolts, it remains perpendicular to the pad or kiss block, and can no longer shift inside the die pocket. In addition, this eliminates the accumulation of metal chips or other debris under the gas spring. When grit and grime build up under a self-contained gas spring, it can become tilted or overstroked. Hose Systems: Gas springs can be hosed together into a system. However, the gas spring s inlet valve must be removed and a fitting installed to permit the attachment of hoses. Note: Always secure gas springs with bolts. The benefits of this method: Gas springs are always balanced in force and pressure. A control panel connected to the system provides the flexibility to adjust the force from outside the tool. Pressure monitors can be connected to the system. They automatically alert the user and/or shut down the press should changes occur in the pressure level. Production can continue should a leak develop. A nitrogen bottle with a regulator can be connected to the control panel to feed a leak until the die is released from production. NOTE: For best results, minimize the number of fittings used in the system. Use only approved hose and fittings. Installation Guidelines: The pocket diameter for a DESIGN2-TITE gas spring should be approximately 2 mm (.08 in.) larger than the body diameter. For optimum performance, the gas spring must be secured in place with an appropriate fastener to ensure that it remains perpendicular to the contacting surface. This eliminates possible debris from building up around the gas spring, leading to side loading or overstroking. When possible, machine drain slots or holes to allow die lubricants to flow away from the gas spring. This prevents flooding of the spring pockets and will keep die lubricants from contaminating the gas spring. It is very important that the piston rod contact a flat, smooth surface. Never allow the top of a piston rod to contact a counter-bored hole, casting or bolt head. Use of a stop block is helpful in preventing the gas spring from being overstroked. The stop block should be equivalent to or greater than the () dimension. Maximum available travel is 100% of stroke. Design should not exceed 90% of available stroke. Charging & Discharging When a gas spring has been in service for a long period of time, it may begin to lose force. DESIGN 2 - TITE gas springs have the additional feature allowing customers to recharge the pressure by using an optional quick disconnect. To adjust or exhaust pressure, use the optional service gauge assembly with DESIGN 2 -TITE gas springs. 23

Rebuild & Charge, Discharge Instructions READY Rebuild and Charge/Discharge Instructions IMPORTANT: DESIGN 2 -TITE gas springs contain high pressure nitrogen gas. To avoid personal injury observe all safety precautions. Prior to working on any gas spring, always wear safety glasses Rebuild and Charge/Discharge Instructions 1. Discharging: Using a flat tip screwdriver, slowly remove the port plug located on base of gas spring. (1.) RL/RLP/RLS shown. A small amount of gas pressure may be present behind installed plug and an audible "wisp" of gas may be heard. Thread READY Part # RT-UAL04.0 QDM Service Gauge Assembly into nitrogen inlet port. Note: Use the RTUAL- G-1/8 x M6 adapter fitting for RLSC1000, RLP500 and the RLM series. Turn inline adjusting screw clockwise until nitrogen pressure can be read on service gauge. Turn exhaust valve knob counterclockwise until all nitrogen pressure has been released (l a). This should be done with gas spring inverted and slowly as some oil may also be mixed with the gas. Using a soft-tipped hammer or mallet, depress piston rod to ensure all gas has been exhausted. Remove service gauge assembly. The gas spring is ready to disassemble. 2. Disassembling: Secure gas spring upright (piston up) in a soft jawed vise or fixture. Using a commercially available adjustable hook spanner wrench, hook onto bronze top cap (RLM series uses flats ) (2.) RL/RLP/RLS shown. (reverse the disassembly directions for the RLSC series, bottom cap 1. picture using flat tip screwdriver 1a. Service Gauge Assembly 2. Counterclockwise adjustable hook face spanner. first ). Unscrew top cap counterclockwise until cap is completely removed from gas spring body. Separate the top cap assembly from the gas spring body. Set top cap assembly aside until unit is completely disassembled. Remove gas spring from the vise and turn it upside down to drain any remaining oil found at bottom of gas spring. Discard oil responsibly. Re-secure spring body in vise in an upside-down (open end- down) position. Remove nitrogen gas inlet valve located within the nitrogen port and discard. Using a pin face spanner wrench or fixture, fit the pins into the holes in spring base and unscrew in a counterclockwise direction. (RLSC series require a custom tool #RT-TOOL-01-RLSC which may be loaned) Remove piston rod and all seals/o-rings from top cap. Care should be taken not to scratch or damage these components as they may be reused later. Remove o-ring from base threads. Note closely how each seal was originally installed to be sure that they are reinstalled in the same direction and position later. Thoroughly clean all components with a suitable solution or solvent. Use compressed air to dry components. 3. Inspecting: Carefully inspect the piston rod (and body bore RLSC), looking for any signs of unusual wear or damage. Look closely at the surface of the piston rod, outside diameter, noting any deep scratches or inclusions that may affect sealing (and body bore RLSC). Visually inspect the bore of top cap thoroughly, noting any signs of uneven wear or side loading; this type of wear 3. Picture showing piston rod and top cap is normally on one side. Inspect body and base for any signs of stress cracks or damage that may affect strength. Discard and replace any component that may be suspect 24

READY Rebuild & Charge, Discharge Instructions Rebuild and Charge/Discharge Instructions (cont.) IMPORTANT: DESIGN 2 -TITE gas springs contain high pressure nitrogen gas. To avoid personal injury observe all safety precautions. 4. Prepare a clean work surface and area to reassemble gas spring. Using the appropriate seal kit, first lubricating all seals and o- rings with *oil. Note the direction of rod seal and rod wiper; both are to be installed the same way they were removed. (Except RLSC series piston which installs from the bottom up for the bore seal) With a small amount of oil, coat the inside diameter of the bore, top cap and piston rod. Carefully install piston rod back into top cap assembly. A soft-tipped hammer or mallet may be required to overcome seal friction. Secure gas spring body in a soft jawed vise or the equivalent. 4. Inserting piston back into gas spring body. 4a. Clockwise turning adjustable hook face spanner. Screw top cap clockwise until cap is completely installed onto gas spring body. Using the spanner wrench, hook onto bronze top cap and torque top cap until tight (4a.). (RLM series use "flat") Remove spring body from vise, turn upside down and re-secure in vise. Screw base onto open end of spring body. Using a pin face spanner wrench, fit the pins into holes of spring base and torque base until tight. Install new nitrogen inlet valve found in the seal kit. not over-torque this valve; READY recommends a "finger or hand-tight" torque. Remove gas spring from vise, turn rod side up. 5. Charging: Be sure rod is fully extended by using threaded hole on piston rod top, or by pulling up on the piston rod until it is fully extended. This prevents a "Firing" condition while charging spring. The "Firing" of a piston rod can damage the rod, top cap and/or other components. Thread READY Part # RT-UAL04.0 QDM Service Gauge Assembly into nitrogen inlet port. Attach nitrogen tank to Service Gauge Assembly. Slowly add nitrogen to gas spring until desired pressure level is reached. not 5. Charging with the Service Gauge Assembly and quick disconnect. exceed the maximum charge level rating of the gas spring. Disconnect nitrogen bottle from service gauge assembly. Exhaust any nitrogen gas that may remain in service gauge assembly through exhaust bleeder valve and remove service gauge assembly. Reinstall port plug into nitrogen spring charge port. 6. Coupling Quick Disconnects (charge fittings): READY Female Quick Disconnect part # RT-QFD-0402 1/4NPT will allow a quick coupling connection to your nitrogen system. (6. shown with READY Part # RT- UAL04.0 QDM Service Gauge Assembly) 6. Quick Disconnect coupling fittings. Place spring on flat, hard surface to prepare for charging. * Body oil: OY100 or equivalent 25

Accessories, Service Gauge READY Accessories To fill or recharge a DESIGN 2 -TITE nitrogen gas spring quickly and easily, order the quick disconnects shown to the right. RLP-750 & 1000, RLSC, RLS, RL: Part #RT-QDM-6251-A RLM-90, 180, 230, 300 & RLP-500: Part #RT-QDM-6-A On Hose Line: Quick Disconnect Female Part #RTQDF-0402 Service Gauge Assembly Part # RTUAL-04.0-QDM This assembly is multi-functional. Use it to fill, empty, or adjust pressure in the gas spring. Installation of this device will result in a nominal loss of pressure. The charge port fitting must be changed when working with the RLM-90, 180, 230, 300 and RLP-500 gas springs. Part # RTUAL-G1/8 x M6: Fitting used with RTUAL-04.0-QDM to fill RLM and RLP-500 gas springs. 1 2 3 4 5 6 7 8 9 10 11 12 Casing/Spool Pressure Adjusting Screw Body Threaded Plug Inlet Valve Outlet Valve Retainer Ring Circlips O-ring O-ring O-ring Gauge To adjust or exhaust pressure of a DESIGN 2 -TITE gas spring, order the service gauge assembly shown above. DESIGN 2 -TITE Ease of Repair is Better by Design DESIGN 2 -TITE provides for quick, safe and simple repairs with our single piece piston rod and threaded bronze top cap. With DESIGN 2 -TITE, gas spring repair is as simple as 1, 2, 3... 1. Discharge the gas spring. Unthread the bronze top cap from the spring body and push the piston rod out the bottom of the top cap. Discard the top cap. 2. Lubricate the piston rod and the three seals contained in the replacement top cap with assembly lubrication. Install the piston rod into the bottom of the replacement top cap and push it up to the lubrication chamber. Add lubrication over the top of the piston rod, filling the chamber. Push the piston rod completely through the top cap. 3. Thread the top cap to the spring body and tighten. With the piston rod fully extended, recharge the gas spring. That s all there is to it, and you re back in production! DESIGN 2 -TITE makes repairs simple and safe. No more hammering out C-style retaining rings. No more fighting to keep the multi-piece cartridge assembly together during handling and installation. No more concerns about installing the cartridge assembly upside down. Most important of all, no more fears that the C-Style retaining ring was damaged or installed improperly. 26 All dimensions and forces are nominal unless otherwise stated.

READY Better by Design DESIGN 2 -TITE Gas Springs Piston Rod One piece construction Hollow piston rod lowers pressure rise Other Gas Springs Dust Cover C-Style Retaining Ring SinterLube Top Cap With Designed with greater bearing area for Improved support and guiding One piece construction creates a mechanical solid for greater structural strength and safety SinterLube alloy material lining provides greater guide and a self-lubricating surface eliminating need to lubricate Multi-piece, Cartridge Assembly Piston Rod Rod Retainer Threaded Upper and Lower Body Construction Retainer Wear Ring ISO standard clamping groove on body Threaded Bottom Cap ISO standard clamping groove ISO standard mounting and charge port Body Assembly Inlet Valve and Port Plug DESIGN 2 -TITE is Better by Design Simple, Solid Construction, Safe, Made of Superior Materials 1. Simple. Our design replaces the many components found on other brands with a one-piece piston rod and a threaded one-piece Sinter-Lube top cap. Our design thus eliminates problems associated with stack-up tolerance affecting overall height and life of the spring. Assembly is simple. The top cap and bottom cap screw into the body, and both are held securely in place with high pressure SAE threads. 2. Solid Construction. By eliminating the retaining ring, our design provides not only structural stability in the upper portion of the gas spring, but precise concentricity and minimum misalignment between the piston rod, top cap and the spring body, all of which extend life. Our SinterLube Top Cap increases guide and eliminates the need to lubricate. This degree of stability, precision and guide during operation is only available with DESIGN 2 -TITE. 3. Safe. With a threaded one-piece Sinter-Lube top cap, we eliminate the retaining ring altogether, and hence, any concern whether the retaining ring is set correctly. 4. Superior Materials. We only use the best and have spared no cost to provide the highest quality. Examine a DESIGN 2 -TITE gas spring and see the difference for yourself. DESIGN 2 -TITE a true advancement in the technology of nitrogen gas springs. With all these features and more, is this not the gas spring you ve always wanted? 27

READY The Innovator of Our Industry SM Our factories and offices: U.S.A. U.K. France Belgium Germany Sweden Netherlands Singapore READY TECHNOLOGY, INC. 333 Progress Rd. Dayton, OH 45449 (800) 543-4355 (937) 866-7200 fax (937) 866-7226 630 Kiser St. Dayton, OH 45404 (800) 367-3437 (937) 228-8181 FAX: (937) 228-2928 BOLDEN DIE SUPPLY P.O. Box 6566 Marietta, GA 30065 (800) 277-4278 (770) 427-4278 fax (770) 427-3282 www.readytechnology.com 2004 READY Technology, Inc. CATALOG # 1204