SERVICE INSTRUCTION 8.1/1 Instructions for the service and the maintenance of GAS SPRINGS Contents Page 1. Safety Regulations... 8.1/2 2. Accessories and spare parts... 8.1/3 3. What You should know about Kaller Gas Springs... 8.1/6 4. Control and Replenishing Armatures... 8.1/7 5. Checking the gas pressure... 8.1/8 6. Checking the spring force... 8.1/8 7. Replenishing the gas... 8.1/9 8. Renovation of Kaller Gas Springs... 8.1/10 9. Renovation of Kaller CU Springs... 8.1/15 8100-2000-02 Read through these instructions carefully before starting any work.
8.1/2 SERVICE INSTRUCTION 1. SAFETY REGULATIONS This symbol indicates WARNING. Personal injury and/ or damage to property may result if the instructions are not followed carefully. Read this instruction carefully before you begin to maintenance the gas spring. Do not do any maintenance on the gas spring if you do not know how to proceed. No service or maintenance on the gas spring should be done, before the spring has been emptied, of gas. The valve on the gas spring must not be removed before the gas has been emptied. Never lean over the valve. Direct the filling port away from you and other people when working with the valve or cover screw. Never use force on the gas spring and protect the gas spring against damage. There is high internal pressure. Do not modify the product. If any gas spring, requiring removal, is connected to a hose system, the gas pressure first must be drained from the control unit. When replenishing gas, only use nitrogen gas N 2. Using other type of gas could result in personal danger. Never fill any gas spring with more pressure than what is permitted. Maximum pressure is 150 bar (15 MPa, 2175 psi). For M, MM, MC 180 bar (18 MPa, 2610 psi). Never replenishing gas, until you are sure everything is correctly assembled. If the guide cannot be pulled out in line with the tube end, something is wrong with the assembly. Check the guide is not upside-down and check that the lock ring is in the groove. If the bottom (only CU) cannot be pulled out in line with the tube end, something is wrong with the assembly. Check the lock ring is in the groove.
SERVICE INSTRUCTION 8.1/3 2. Accessories and spare parts The following accessories and spare parts can be ordered from us or from our representatives Control armature*... 4015072 Force test bench for gas springs M, MM, MC and 250-500.... 1014062 Replenishing armature* with stop valve... 3015075-2000 *Adapter 3014016 (G 1/8") and 3014021 (M6) are enclosed with the armature. Force test bench for gas springs 750-7500 and CU, (exception TU 10000, CU 11300 and CU 18300)... 1013143
8.1/4 SERVICE INSTRUCTION Tool kit for renovation of gas springs Tool kit complete... 1014779 Tool kit M, MM, MC... 1214779 Tool kit 250-7500... 1114779 Tool kit CU... 1314779
SERVICE INSTRUCTION 8.1/5 Repair kits TU, TC, TB Gas spring Kit part No. 250 TC... 2013691-0250 500 TC... 2013691-0500 750 TS/TM/TMS... 2013691-0750 750 TU/TC... 2014068-01 1500 TU/TC... 2014068-02 3000 TU/TC... 2014068-03 5000 TU/TC... 2014068-04 7500 TU/TC... 2014068-09 1000 TC/TC... 2014068-10 750 TB... 2014068-05 1500 TB... 2014068-06 3000 TB... 2014068-07 5000 TB... 2014068-08 M/MM/MC... 2013691-0150 ISO-MC... 2016406-01 500 K/KS... 3016189 750 K/KS... 3016190 1000 CU... 2014493-0100 1800 CU... 2014493-0180 4700 CU... 2014493-0470 7500 CU... 2014493-0750 11800 CU... 2014493-1180 18300 CU... 2014493-1830 250 HT... 3015091 750 HT... 2015092-0750 CU M, MM, MC
8.1/6 SERVICE INSTRUCTION 3. What you should know about Kaller Gas Springs Kaller gas springs are designed for extremely long service life, and require a minimum of service and maintenance. The pressure medium is nitrogen, which is why the parts of the gas springs are not subjected to normal corrosion. Service is restricted to checking the attachment elements and checking or modifying the gas pressure to achieve a suitable spring force. The spring force is checked in conjunction with the inspection of the tool. When the gas spring has been in use for a long time and starts to lose some of the spring force, it is normally a sign that the sealing parts have become worn. It is then time to renovate the gas spring by replacing the guide and the seals. The gas spring can be used again. Renovation of the gas spring is performed with the help of simple accessories after reading these instructions carefully. Special tool kits are supplied by us or our representatives. Max. filling pressure is 150 bar (15 MPa, 2175 psi). For M, MM, MC 180 bar (18 MPa, 2610 psi). The gas spring is filled to the maximum pressure at delivery, unless otherwise stated on the order. If the pressure is too high for the operation concerned, it can be reduced (and checked) by means of a control armature. The filling pressure should, however, not be less than 50 bar. If you require a lower filling pressure, seek the advice of your supplier. The filling pressure can be calculated according to the formula below. The pressure build-up in a gas spring is linked with the stroke length in question. The gas spring can be mounted in any desired position. Side forces should be avoided. High side or oblique forces shorten the service life of the spring. Our flexible attachment should be used when side forces cannot be entirely avoided. When mounting a gas spring in the tool, a stroke reserve should always be provided (refer to technical documentation). Calculation of filling pressure, to achieve spring force other than standard NB! not for M, MM, MC Desired force = X kg X Filling pressure= 150 Spring force at 150 bar For M, MM, MC: Filling pressure = 180 X 200 (Spring force at 180 bar) Example: A 250 spring to have a desired force of 180 kg. Filling pressure = 150 180 250 = 108 bar
SERVICE INSTRUCTION 8.1/7 4. Control armature, P/N 4015072 Replenishing armature, P/N 3015075-2000 The control armature (4015072) is used for measuring the pressure and reducing the pressure in the gas spring. It consists of a pressure regulator with a manometer (graduated in bar and psi). Fitted on the upper side of the armature there is a knurled knob (A) with which the armature is screwed securely into the gas spring s filling port, and also a smaller knob (B) with which a release pin (C) can be screwed down and thereby open and close the gas spring valve. Before being fitted on the gas spring, the pin must be screwed upwards inside the lower edge of the M6/ G 1/8" thread to prevent uncontrolled release of gas just when the regulator is about to be screwed in securely. On the side of the regulator there is a knob (D) with which the pressure can be reduced in the gas spring and any overpressure in the regulator removed. Before mounting, the knob must be screwed in (closed). There is also a blind plug on the side of the armature. B The replenishing armature (3015075-2000) consists of a pressure regulator with a manometer as described above. The blind plug is replaced here by a 2-metre long high pressure hose with a stop valve for connection to the nitrogen cylinder. The connection thread on the regulator is a M6 thread. When the armature is delivered, it also contains two adapters, one for the G 1/8" filling port, and one for the M6 filling port on models with the port in the piston rod (M, MM, MC, 250, TS 750, K/KS 500 and 750). Armature 4015072 A) Knurled knob B) Knob that activates the release pin C) Release pin D) Knob for gas release D A C
8.1/8 SERVICE INSTRUCTION 5. Checking the gas pressure using a control armature Equipment required: Control armature, P/N 4015072 Allen key 5:1) Unscrew the gas spring s cover screw from the filling port. For safety, never lean over the valve. On M, MM, MC, 250, TS 750, K/KS 500 and 750 and old models of CU gas springs, the valve is in the piston rod. On TU/TC 500-10000 the filling port is in the tube. On new models of CU the filling port is in the bottom. 5:2) Screw the armature securely in the gas spring by means of knob A. Open the valve slowly and carefully using knob B. Turn in a clockwise direction. Open only until you can hear the gas. If you screw too far the valve may become damaged, and with too much release of gas there may be the formation of a vortex that may well damage the valve beyond repair. Read off the pressure from the manometer. 6. Checking the spring force by means of a test bench Equipment required: a) Force test bench P/N 1014062 (gas springs M, MM, MC, 250 and 500) b) Force test bench P/N 1013143 (gas springs 750-7500, and CU springs except for CU 11300 and 18300) 6:1) Set the force test bench at the correct stroke length. 6:2a) 6:2b) Pump up the jack until the force test bench reaches the stop position. Pump up the jack until the gas spring s piston rod reaches the pressure plate and the manometer gives a small reading. Pump two more full strokes using the handle of the jack. 6:3) The gas spring force can be read on the manometer. 6:4) Release the pressure on the jack. 5:3) If the valve is leaking, it must be replaced. Refer to chapter 8, items 8:3 and 8:20. Control armature P/N 4015072 Test bench P/N 1013143
SERVICE INSTRUCTION 8.1/9 7. Replenishing the gas Equipment required: Replenishing armature P/N 3015075-2000 Nitrogen bottle Allen key Vice with smooth jaws 7:1) Clamp the gas spring carefully into the vice. Unscrew the gas spring s cover screw from the filling port. For safety, never lean over the valve. On M, MM, MC, 250, TS 750, K/KS 500 and 750 and old models of CU gas springs, the filling port is in the piston rod. On TU/TC 500-10000 the filling port is in the tube. On new models of CU gas springs the filling port is in the bottom. 7:2) Connect the replenishing armature hose to the nitrogen cylinder. 7:3) Screw the armature securely in the gas spring filling port by means of knob A. Open the valve slowly and gently using knob B, turn in a clockwise direction. Open only until you can hear the gas. If you screw too far the valve may become damaged, and with too much release of gas there may be the formation of a vortex that may well damage the valve beyond repair. 7:4) Fill with gas until the manometer shows the desired pressure by opening the nitrogen bottle carefully. Note that the maximum pressure is 150 bar (15 MPa, 2175 psi). For M, MM, MC 180 bar (18 Mpa, 2610 psi). Then close the nitrogen bottle. Regulate the gas flow by the existing stop valve on the armature. 7:5) On completion of replenishing, close the gas spring valve using knob B. Turn in an anticlockwise direction. If the pressure is too high, it can be lowered with knob D before knob B is closed. 7:6) Empty the gas inside the armature by closing the stop valve and opening with knob D until there is no more gas. 7:7) When the armature will not be used any more, empty the gas inside the armature and hose by closing the nitrogen bottle and open knob D until there is no more gas. Make sure the stop valve on the armature is open. 7:8) Unscrew the armature fully using knob A. Check to make sure that the valve seals. Tighten the cover screw securely. 7:9) If the valve is leaking, it must be replaced. Refer to chapter 8, items 8:3 and 8:20. Replenishing gas through piston rod Replenishing gas through tube
8.1/10 SERVICE INSTRUCTION 8. Renovation of Kaller gas springs A J B C K D Category: a) = Gas springs M, MM, MC, 250, TS 750, K/KS 500 and 750 (valve in the piston rod) b) = Gas springs TU/TC 500, 750, 1500, 3000, 5000, 7500, 10000 (valve in the tube) Disassembly E F G H J K a) Valve in the piston rod b) Valve in the tube Kaller Gas spring A) Piston Rod B) Dirt protection ring C) Lock ring D) Guide E) Tube F) Piston (consists of two halves) G) Guide ring H) Oil J) Cover screw K) Valve 8:1) To obtain an easy working position, clamp the spring in a vice. Put the gas spring in a leaning position (about 30 ) with the opening of the valve upwards for all models in category b, except for the TU/TC 500 and 750 where the opening should be facing the floor. This is to prevent oil from leaking out during the servicing. 8:2a) 8:2b) Unscrew the M6 cover screw (J) in the top of the piston rod with a 3 mm Allen key. Unscrew the G 1/8 cover screw (J) on the tube with a 5 mm Allen key.
SERVICE INSTRUCTION 8.1/11 Type 1 Type 2 8:3) If there is still gas in the spring, release it by screwing the threaded end of the valve tool into the filling port until the valve needle opens. The valve (K) must not be unscrewed until the piston rod can be pushed down by hand. Then unscrew the valve with the opposite side of the valve tool. Take out the valve with the valve pliers. 8:5) Remove the lock ring (C) using the lock ring tool. This tool is available in two versions. With type 1, the lock ring is removed by gently bending the end of the ring upwards, towards you. With type 2, the lock ring is also pulled up and is easily removed if the support is as close to the tool head as possible. Tighten the support, steady it with your thumb and lever downwards. 8:4) Tap the guide (D) down, using a hammer and a mandrel, so that the lock ring (C) is exposed. For springs in category b, remove the dirt protection ring (B) that becomes loose during the tapping. 8:6a) 8:6b) Pull out the piston rod (A) and the guide (D) using the T-handle. Pull out the piston rod (A) including the piston halves (F) and the guide (D), using the T-handle.
8.1/12 SERVICE INSTRUCTION Inspection 8:9) Clean the parts that will be reused. 8:10) Make a visual check of the piston rod and the inside of the tube. There must not be any scratches. The gas spring is sensitive to damage of the piston rod. If you are in doubt, replace the piston rod. 8:7a) 8:7b) Remove the guide (D) from the piston rod by pulling the guide upwards. Remove the guide ring (G), the two piston halves (F) and the guide (D) from the piston rod. The guide is removed by either pulling it upwards or by turning the piston rod upside down and then pressing the guide downwards. Assembly 8:11) Take the repair kit. 8:12b) Fit the piston halves (F) and the guide ring (G) on the piston rod. 8:8a) 8:8b) Save the piston rod (A) and the tube (E). Save the piston rod (A), the tube (E) and the two piston halves (F). 8:13) Oil the seals and the bushing (E) on the guide (D) with an oily finger. Note! Be careful not to apply too much oil since that may cause a gas leakage. 8:14) Fit the guide (D) on the piston rod (A). One of the guide ends has a smaller diameter. This diameter is smaller to fit the lock ring. The end with the smaller diameter should be upwards, facing the ceiling, when the guide is fitted on the piston rod.
SERVICE INSTRUCTION 8.1/13 8:15) Oil the inside of the upper tube end to prevent damage to the guide O-ring. 8:16) Fill the correct amount of millilitres of lubricating oil in the tube (refer table below). Before the oil is poured into the tube, position the tube so that the oil level won t exceed the hole in the bottom. Model M, MM, MC, ISO-MC TC 250, HT 250 TC 500 TU/TC/TS/TM/TMS/HT 750 TU/TC 1500 TU/TC 3000 TU/TC 5000 TU/TC 7500 K 500 TU/TC 10000 stroke 25-99 mm TU/TC 10000 stroke 100-300 mm KS 500 stroke 12,7-49 mm KS 500 stroke 50-127 mm K/KS 750 stroke 8-49 mm K/KS 750 stroke 50-127 mm TB 750 TB 1500 TB 3000 TB 5000 Oil 2 ml 4 ml 8 ml 10 ml 30 ml 30 ml 40 ml 60 ml 90 ml 140 ml 8 ml 5 ml 8 ml 5 ml 10 ml 30 ml 40 ml 60 ml 120 ml 8:17) Push in the piston rod with guide into the tube. Tap down the guide (D) using a hammer and a mandrel. 8:18) Fit the lock ring (C) into the groove in the tube by pushing one of the lock ring ends into the groove, steadying it with your thumb and then hit on the ring until it snaps into the groove. You can hear a clicking sound when it falls into position.
8.1/14 SERVICE INSTRUCTION 8:19) Pull out the piston rod (A) and the guide (D) using the T-handle. Pull until the guide is in line wih the tube end. Note! If the guide cannot be placed in line with the upper end of the tube there is something wrong with the assembly. Note! Gas should not be put into the spring until the guide is in line with the tube end. 8:20) Screw in the valve (K) using the valve tool. The valve should only be tightened with finger strength. 8:21a) Fill the spring with gas. See chapter 7. Fit the M6 cover screw (J) in the piston rod. Note that it has a sealing function and always must be fitted and tightened on the spring. 8:21b) Fill the spring with gas. See chapter 7. Fit the G 1/8" cover screw (J) in the tube and tighten with 15-18 Nm. Note that it has a sealing function and always must be fitted and tightened on the spring. Important points to remember Never fill any gas spring with more gas than what is permitted. Maximum pressure is 150 bar (15 MPa, 2175 psi). For M, MM, MC 180 bar (18 Mpa, 2610 psi). When you have unscrewed the cover screw: Never lean over the valve. Direct the filling port away from you when working with the valve or cover screw. Never use force on the gas spring and protect the gas spring against damage. High internal pressure. Keep the gas springs very clean to achieve the maximum service life. All gas springs carry this label (or on some markets a similar label). This label must not be removed or rendered illegible. Tel. +46 140 571 00, Telefax +46 140 571 99 Box 216, SE-573 23 Tranås Sweden made by FÅR EJ ÖPPNAS - HÖGT TRYCK. MAX FYLLNINGSTRYCK 150 BAR. SKYDDAS MOT SKADOR. DO NOT OPEN - HIGH PRESSURE. FILLING PRESSURE MAX 150 BAR. PROTECT AGAINST DAMAGE. NICHT ÖFFNEN - HOHER DRUCK. MAX FÜLLDRUCK 150 BAR. VOR BESCHÄDIGUNG SCHÜTZEN. NE PAS OUVRIR - HAUTE PRESSION. PRESSION DE REMPLISSAGE MAX 15 MPa. PROTEGER CONTRE DOMMAGE. 4014535 8:22b) Fit the dirt protection ring (B) so that it fits in line with the end of the tube and guide. The function of the dirt protection ring is to prevent dirt from penetrating into the gas spring.
SERVICE INSTRUCTION 8.1/15 9. Renovation of CU springs H J K G F L Category: a) = Model with the valve in the piston rod b) = Model with the valve in the bottom Disassembly E D C B A G a) Valve in the piston rod H J L 9:1a) Clamp the spring with the piston rod upwards in a vice. Clamp at the upper part of the tube above the C-groove. Unscrew the M6 cover screw with a 3 mm Allen key. F E K D C B A b) Valve in the bottom A) Bottom B) Lock ring C) Support ring D) O-ring E) Guide ring F) Piston seal G) Support ring H) Guide ring J) Piston K) Cover Screw L) Valve 9:1b) Clamp the spring with the bottom upwards in a vice. Fasten at the upper part of the tube, close to the piston rod. Unscrew the G 1/8" cover screw (K) with a 5 mm Allen key. If there is no gas left in the spring the bottom (A) may move. If so, gently fasten the tube at its lower end.
8.1/16 SERVICE INSTRUCTION 9:2) If there is still gas in the spring, release it by screwing the threaded end of the valve tool into the filling port until the valve needle opens. The valve (L) must not be unscrewed until the piston rod can be pushed down by hand or be tapped down with a plastic hammer. Then unscrew the valve with the opposite end of the valve tool and take the valve out with the valve pliers. 9:4a) Turn the tube in upright position, hit the rod (J) until the bottom (A) comes out of the tube and continue hitting until the rod comes out. Sometimes great force is required when the sealing lip passes the lock ring groove. 9:3) Tap down the bottom (A) with a hammer and a mandrel until the lock ring (B) is free (for the springs with the valve in the piston rod, you first turn the spring upside down). Remove the lock ring with the lock ring tool (the tool with the concave tip). Bend the lock ring upwards and inwards. 9:4b) Pull out the bottom (A), using the T- handle. Pour out the oil and press out the rod (J).
SERVICE INSTRUCTION 8.1/17 Inspection 9:7) Wash the tube, the rod and the bottom. 9:8) Inspect the rod and the inside of the tube to ensure that there are no defects. There might be scratches in the tube if the rod has worked with side load. If there are scratches replace the parts. 9:5) Remove the guide ring (E), the support ring (G) and the seal (F) from the rod. For dismounting the seal, a tool is required to lift it, for instance a screw driver. Note! Be careful to ensure there are no scratches on the rod, where the seal is placed. On the smaller models it can be difficult to lift off the seal by hand. If so, lift the seal and cut it loose. Assembly 9:6) Remove the guide ring (H) from the tube. Remove the O-ring (D) and the support ring (C) from the bottom. 9:9) Oil the rod seal (F) gently. Oil the guiding sleeve and slip on the seal with the black O-ring upwards. (For some larger models the seal can be slipped on the rod by hand). Hit or press on the seal with the plastic mandrel. (The guiding sleeve will get stuck in the plastic mandrel but can be taken out with a screw driver or something similar.) Adjust the O-ring under the seal ring and push down the seal.
8.1/18 SERVICE INSTRUCTION 9:10) Fit the guide ring (E) on the piston and then fit the support ring (G) above the piston seal (F). Note! If the support ring is chamfered, the chamfering should be upwards. 9:12) Fit the rod guide (H) by pressing it down into the tube. If the rod guide is not divided (only some models), bending it to a kidney shape and press it down into the tube. The plane part of the lip on the rod guide should be upwards (refer figure below). 9:11) Fit the support ring (C) and the O- ring (D) on the bottom. The O-ring should be above the guide ring. Oil the O-ring before assembly. 9:13) Oil the inside of the tube end with an oily finger and press the rod (J) into the tube until it stops against the tube stop. The piston rod should then be completely out. Fill with oil according to directions (Refer to table next page).
SERVICE INSTRUCTION 8.1/19 Model CU 1000 CU 1800 CU 4700 CU 7800 CU 11800 CU 18300 Oil 2 ml 4 ml 6 ml 10 ml 20 ml 30 ml 9:16a) Turn the tube so that the bottom tube end rests against the bottom of the vice. Fill the tube carefully with compressed air through the opening of the valve so that the bottom (A) is pressed down into the correct position, that is, in line with the tube end. 9:16b) Pull out the bottom (A) using the T- handle until the bottom is in the same plane as the tube end. 9:17) Check that the lock ring (B) (or in some cases, the lock ring halves) is still in it s groove. Note! Gas must not be filled in the spring until the bottom is in its correct position, that is, in line with the tube end. 9:14) Fit and tap down the bottom (A) until the lock ring groove is visible. 9:18) Fit the valve (L) into the filling port with the valve tool. Note! Finger strength is enough to tighten the valve. 9:19) Fill the spring with the desired gas pressure. Note that the maximum pressure is 150 bar (15 MPa, 2175 psi). 9:20a) Fit the M6 cover screw (K) in the piston rod. Note that it has a sealing function and always must be fitted and tightened on the spring. 9:15) Fit the lock ring (B) into the lock ring groove by pushing one of the ends into the groove and then press or hit until it snaps into the groove. You can hear a clicking sound when it falls into position. Older CU 1800 has two lock ring halves that are fitted into the groove, make sure that both halves are in the right position. 9:20b) Fit the G 1/8" cover screw (K) in the tube and tighten with 15-18 Nm. Note that it has a sealing function and always must be fitted and tightened on the spring.
Tel. +46 140-571 00 Telefax +46 140-571 99 PRINTED IN SWEDEN 1999
SERVICE INSTRUCTION 8.2/1 G J K H L K J G F D C E A M Accumulator Ø 63, 80, 100 A) Cover screw B) Valve C) Lock screw D) Plate E) Gas gable F) Oil gable Materials and tools 4 mm Allen key Repair kits (P/N 3014532-063, Ø 63) (P/N 3014532-080, Ø 80) (P/N 3014532-100, Ø 100) Valve tool (P/N 3014172-01) Lock ring tool (P/N 3015464) DISASSEMBLY 1. Disconnect the accumulator from the hydraulic system Note! Make sure that the hydraulic system is not under pressure. Disconnect the accumulator from the hydraulic system. Empty the accumulator of remaining oil. 2. Empty the accumulator of gas Unscrew the coverscrew (A) with a 4 mm Allen key. The cover screw is in the middle of the gas gable. Disassemble the rubber steel plate. Screw the threaded end of the valve tool into the filling port until you can hear the gas coming out. When there is no more gas left, unscrew the valve with the opposite end of the tool. Take the valve out with the valve pliers. G) Lock ring H) Piston complete J) Support ring K) O-ring L) Tube M) Rubber steel plate Plastic hammer 0,4-0,6 kg T-handle (P/N 502241) Plastic sleeve (length depending on the size of the accumulator) Hydraulic oil Clean rags 3. Disassembly the gables Unscrew the screws (C) and the lock plates (D) from the gables using a 4 mm Allen key. Disassembly the gables (E and F) by tapping them down with a plastic hammer about 20-25 mm, until the lock ring is exposed. The lock ring (G) are removed by gently bending the end of the lock ring upwards using the lock ring tool. Pull out the gables. Screw the T-handle into the filling port in the gas gable and pull out the gable. For the oil gable, use the adapter to pull out the gable. B
8.2/2 SERVICE INSTRUCTION 4. Disassembly of the piston Use a plastic hammer and rod or sleeve, long enough to get the piston out (H). Tap out the piston towards the oil side gable by putting the rod or the sleeve in the piston where it is concave and then tap. That way, the risk of damage to the inner surface of the tube is reduced. Save the tube and the gables. The piston can be thrown away since it is enclosed, complete with seals, in the repair kit. 5. Checking and cleaning Disassembly the seals from the gables (J and K). Clean all details. Always use clean rags since cleanliness is important in order to obtain a long lifetime of the product. Check the inside of the tube and make sure that there are no scratches. Scratches can appear for example after bad filtration of the hydraulic oil. If there are scratches that you can feel with a sharp object, the tube must be thrown away. 6. Good things to know If the piston has been working in one end of the tube, you can turn the tube and make the piston work on an untouched surface. The two ends of the tube are similar. Mark where each gable has been placed, and change the order at the assembly. ASSEMBLY 7. Fitting of the seals Fit the support ring (K) and the O-ring (J) on the gables. Note! The order of the rings, the support ring should be outmost, closest to the atmosphere side. 8. Fitting of the piston Oil the piston (H), it s seals and the inner surface of the tube with the recommended hydraulic oil. Turn the piston with it s oil end (the convex end) upwards and push the piston down as far as possible. When the first of the piston seals reaches the lock ring groove, pushing becomes difficult. Then use a plastic hammer and a sleeve and tap the piston down about 10 cm. Make sure that the tube remains clean. 9. Fitting of the gables Oil the seals on the gables (J and K). Fit the gas gable against the concave end of the piston. Press down the gable by hand as far as possible and then use a plastic hammer. Tap down the gable until the lock ring groove is visible. Note! Tap with the hammer in the centre of the gable so that it doesn t become uneven. 10. Fitting of lock rings and lock screws Fit the lock ring (G) into it s lock ring groove. Push one of the lock ring ends into the groove, fix the ring with your thumb and tap on the ring until it snaps into position. You can hear a clicking sound when this happens. Screw the T-handle into the gas gable and pull it out towards the lock ring. Pull out the oil gable using the adapter. Fit the screws (C) and the plates (D) on both gables. 11. Fitting of the valve and replenishing of gas Fit the valve (B) and tighten 0,028 Nm with the valve tool. Fill the accumulator with gas. See separate instruction. After filling whit gas, fit the cover screw (A) and the rubber steel plate (M). Note! The plate has a sealing function and must be there. Tighten the cover screw with a 4 mm Allen key.