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 Read through these instructions carefully before starting any work. 8100-2000-02
Transcript
SERVICE INSTRUCTION 8.1/1
Instructions for the service and themaintenance of
GAS SPRINGS
Contents Page
1. Safety Regulations ....................................... 8.1/22. Accessories and spare parts ........................ 8.1/33. What You should know about Kaller Gas Springs ....................................... 8.1/64. Control and Replenishing Armatures ........... 8.1/75. Checking the gas pressure ........................... 8.1/86. Checking the spring force ............................. 8.1/87. Replenishing the gas .................................... 8.1/98. Renovation of Kaller Gas Springs .............. 8.1/109. Renovation of Kaller CU Springs ................ 8.1/15
Read through these instructions carefully beforestarting any work.
8100-2000-02
8.1/2 SERVICE INSTRUCTION
1. SAFETY REGULATIONSThis symbol indicatesWARNING. Personal injury and/or damage to property mayresult if the instructions arenot followed carefully.
• Read this instruction carefullybefore you begin to mainte-nance the gas spring.
• Do not do any maintenance onthe gas spring if you do notknow how to proceed.
• No service or maintenance onthe gas spring should be done,before the spring has beenemptied, of gas.
• The valve on the gas springmust not be removed beforethe gas has been emptied.
• Never lean over the valve.Direct the filling port awayfrom you and other peoplewhen working with the valve orcover screw.
• Never use force on the gasspring and protect the gasspring against damage. Thereis high internal pressure.
• Do not modify the product.
• If any gas spring, requiringremoval, is connected to ahose system, the gas pressurefirst must be drained from thecontrol unit.
• When replenishing gas, onlyuse nitrogen gas N 2. Usingother type of gas could resultin personal danger.
• Never fill any gas spring withmore pressure than what ispermitted. Maximum pressureis 150 bar (15 MPa, 2175 psi).For M, MM, MC 180 bar(18 MPa, 2610 psi).
• Never replenishing gas, untilyou are sure everything iscorrectly assembled.
• If the guide cannot be pulledout in line with the tube end,something is wrong with theassembly. Check the guide isnot upside-down and checkthat the lock ring is in thegroove.
• If the bottom (only CU) cannotbe pulled out in line with thetube end, something is wrongwith the assembly. Check thelock ring is in the groove.
SERVICE INSTRUCTION 8.1/3
2. Accessories and spare parts
The following accessories and spare partscan be ordered from us or from our repre-sentatives
Control armature* ............................ 4015072
1000 CU ............................... 2014493-0100 1800 CU ............................... 2014493-0180 4700 CU ............................... 2014493-0470 7500 CU ............................... 2014493-075011800 CU ............................... 2014493-118018300 CU ............................... 2014493-1830
Kaller gas springs are designed for ex-tremely long service life, and require a mini-mum of service and maintenance. The pres-sure medium is nitrogen, which is why theparts of the gas springs are not subjected tonormal corrosion. Service is restricted tochecking the attachment elements andchecking or modifying the gas pressure toachieve a suitable spring force. The springforce is checked in conjunction with theinspection of the tool.
When the gas spring has been in use for along time and starts to lose some of thespring force, it is normally a sign that thesealing parts have become worn. It is thentime to renovate the gas spring by replacingthe guide and the seals. The gas spring canbe used again. Renovation of the gas springis performed with the help of simple acces-sories after reading these instructions care-fully. Special tool kits are supplied by us orour 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 maximumpressure at delivery, unless otherwise statedon the order. If the pressure is too high forthe operation concerned, it can be reduced(and checked) by means of a control arma-ture. The filling pressure should, however, notbe less than 50 bar. If you require a lowerfilling pressure, seek the advice of yoursupplier.
The filling pressure can be calculatedaccording to the formula below.
The pressure build-up in a gas spring islinked with the stroke length in question.
The gas spring can be mounted in any de-sired position. Side forces should be avoided.High side or oblique forces shorten the serv-ice life of the spring. Our flexible attachmentshould be used when side forces cannot beentirely avoided. When mounting a gasspring in the tool, a stroke reserve shouldalways be provided (refer to technical docu-mentation).
Example: A 250 spring to have adesired force of 180 kg.
Filling pressure = 150 • 180250
= 108 bar
For M, MM, MC:
Filling pressure = 180 •X
200
(Spring force at 180 bar)
Calculation of filling pressure, toachieve spring force other thanstandard
NB! not for M, MM, MC
Desired force = X kg
Filling pressure= 150 •X
Spring force at 150 bar
SERVICE INSTRUCTION 8.1/7
B
A C
D
The replenishing armature (3015075-2000)consists of a pressure regulator with a ma-nometer as described above. The blind plugis replaced here by a 2-metre long highpressure hose with a stop valve for connec-tion to the nitrogen cylinder.
The connection thread on the regulator is aM6 thread. When the armature is delivered, italso contains two adapters, one for theG 1/8" filling port, and one for the M6 fillingport on models with the port in the piston rod(M, MM, MC, 250, TS 750, K/KS 500and 750).
Armature 4015072
A) Knurled knobB) Knob that activates the release pinC) Release pinD) Knob for gas release
4. Control armature, P/N 4015072Replenishing armature,P/N 3015075-2000
The control armature (4015072) is used formeasuring the pressure and reducing thepressure in the gas spring. It consists of apressure regulator with a manometer (gradu-ated in bar and psi).
Fitted on the upper side of the armaturethere is a knurled knob (A) with which thearmature is screwed securely into the gasspring’s filling port, and also a smaller knob(B) with which a release pin (C) can bescrewed down and thereby open and closethe gas spring valve. Before being fitted onthe gas spring, the pin must be screwedupwards inside the lower edge of the M6/G 1/8" thread to prevent uncontrolled releaseof gas just when the regulator is about to bescrewed in securely.
On the side of the regulator there is a knob(D) with which the pressure can be reducedin the gas spring and any overpressure inthe regulator removed. Before mounting, theknob must be screwed in (closed). There isalso a blind plug on the side of the arma-ture.
8.1/8 SERVICE INSTRUCTION
5. Checking the gas pressureusing a control armature
5:1) Unscrew the gas spring’s cover screwfrom the filling port. For safety, neverlean over the valve . On M, MM, MC,250, TS 750, K/KS 500 and 750 andold models of CU gas springs, thevalve is in the piston rod. On TU/TC500-10000 the filling port is in thetube. On new models of CU the fillingport is in the bottom.
5:2) Screw the armature securely in thegas spring by means of knob A. Openthe valve slowly and carefully usingknob B. Turn in a clockwise direction.Open only until you can hear the gas.If you screw too far the valve maybecome damaged, and with too muchrelease of gas there may be theformation of a vortex that may welldamage the valve beyond repair.Read off the pressure from the ma-nometer.
5:3) If the valve is leaking, it must bereplaced. Refer to chapter 8, items8:3 and 8:20.
Control armature P/N 4015072
6. Checking the spring force bymeans of a test bench
Equipment required:
a) Force test bench P/N 1014062 (gassprings M, MM, MC, 250 and 500)
b) Force test bench P/N 1013143 (gassprings 750-7500, and CU springsexcept for CU 11300 and 18300)
6:1) Set the force test bench at the correctstroke length.
6:2a) Pump up the jack until the force testbench reaches the stop position.
6:2b) Pump up the jack until the gasspring’s piston rod reaches the pres-sure plate and the manometer givesa small reading. Pump two more fullstrokes using the handle of the jack.
6:3) The gas spring force can be read onthe manometer.
6:4) Release the pressure on the jack.
Test bench P/N 1013143
SERVICE INSTRUCTION 8.1/9
7. Replenishing the gas
Equipment required :
Replenishing armature P/N 3015075-2000Nitrogen bottleAllen keyVice with smooth jaws
7:1) Clamp the gas spring carefully intothe vice. Unscrew the gas spring’scover screw from the filling port.For safety, never lean over thevalve. On M, MM, MC, 250, TS 750,K/KS 500 and 750 and old models ofCU gas springs, the filling port is inthe piston rod. On TU/TC 500-10000the filling port is in the tube. On newmodels of CU gas springs the fillingport is in the bottom.
7:2) Connect the replenishing armaturehose to the nitrogen cylinder.
7:3) Screw the armature securely in thegas spring filling port by means ofknob A. Open the valve slowly andgently using knob B, turn in a clock-wise direction. Open only until youcan hear the gas. If you screw too farthe valve may become damaged, andwith too much release of gas theremay be the formation of a vortex thatmay well damage the valve beyondrepair.
7:4) Fill with gas until the manometershows the desired pressure by open-ing the nitrogen bottle carefully. Notethat the maximum pressure is 150bar (15 MPa, 2175 psi). For M, MM,MC 180 bar (18 Mpa, 2610 psi) .Then close the nitrogen bottle. Regu-late the gas flow by the existing stopvalve on the armature.
7:5) On completion of replenishing, closethe gas spring valve using knob B.Turn in an anticlockwise direction. Ifthe pressure is too high, it can belowered with knob D before knob B isclosed.
7:6) Empty the gas inside the armature byclosing the stop valve and openingwith knob D until there is no moregas.
7:7) When the armature will not be usedany more, empty the gas inside thearmature and hose by closing thenitrogen bottle and open knob D untilthere is no more gas. Make sure thestop valve on the armature is open.
7:8) Unscrew the armature fully usingknob A. Check to make sure that thevalve seals. Tighten the cover screwsecurely.
7:9) If the valve is leaking, it must bereplaced. Refer to chapter 8, items8:3 and 8:20.
Replenishing gas through tubeReplenishing gas through piston rod
8.1/10 SERVICE INSTRUCTION
8. Renovation of Kaller gas springs
a) Valve in the piston rod b) Valve in the tube
Kaller Gas spring
A) Piston RodB) Dirt protection ringC) Lock ringD) GuideE) TubeF) Piston (consists of two halves)G) Guide ringH) OilJ) Cover screwK) Valve
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 thetube)
Disassembly
8:1) To obtain an easy working position,clamp the spring in a vice. Put thegas spring in a leaning position(about 30°) with the opening of thevalve upwards for all models in cat-egory b, except for the TU/TC 500and 750 where the opening shouldbe facing the floor. This is to preventoil from leaking out during the servic-ing.
8:2a) Unscrew the M6 cover screw (J) inthe top of the piston rod with a 3 mmAllen key.
8:2b) Unscrew the G 1/8” cover screw (J)on the tube with a 5 mm Allen key.
E
F
D
C
B
A
K
J
H
G
K
J
SERVICE INSTRUCTION 8.1/11
8:3) If there is still gas in the spring,release it by screwing the threadedend of the valve tool into the fillingport until the valve needle opens. Thevalve (K) must not be unscreweduntil the piston rod can be pusheddown by hand. Then unscrew thevalve with the opposite side of thevalve tool. Take out the valve with thevalve pliers.
8:4) Tap the guide (D) down, using ahammer and a mandrel, so that thelock ring (C) is exposed. For springsin category b, remove the dirt protec-tion ring (B) that becomes looseduring the tapping.
Type 1 Type 2
8:5) Remove the lock ring (C) using thelock ring tool. This tool is available intwo versions. With type 1, the lockring is removed by gently bending theend of the ring upwards, towards you.With type 2, the lock ring is alsopulled up and is easily removed if thesupport is as close to the tool headas possible. Tighten the support,steady it with your thumb and leverdownwards.
8:6a) Pull out the piston rod (A) and theguide (D) using the T-handle.
8:6b) Pull out the piston rod (A) includingthe piston halves (F) and the guide(D), using the T-handle.
8.1/12 SERVICE INSTRUCTION
8:7a) Remove the guide (D) from the pistonrod by pulling the guide upwards .
8:7b) Remove the guide ring (G), the twopiston halves (F) and the guide (D)from the piston rod. The guide isremoved by either pulling it upwardsor by turning the piston rod upsidedown and then pressing the guidedownwards.
8:8a) Save the piston rod (A) and the tube(E).
8:8b) Save the piston rod (A), the tube (E)and the two piston halves (F).
Inspection
8:9) Clean the parts that will be reused.
8:10) Make a visual check of the piston rodand the inside of the tube. Theremust not be any scratches. The gasspring is sensitive to damage of thepiston rod. If you are in doubt, re-place the piston rod.
Assembly
8:11) Take the repair kit.
8:12b) Fit the piston halves (F) and theguide ring (G) on the piston rod.
8:13) Oil the seals and the bushing (E) onthe guide (D) with an oily finger.Note! Be careful not to apply toomuch oil since that may cause a gasleakage.
8:14) Fit the guide (D) on the piston rod(A). One of the guide ends has asmaller diameter. This diameter issmaller to fit the lock ring. The endwith the smaller diameter should beupwards, facing the ceiling, when theguide is fitted on the piston rod.
SERVICE INSTRUCTION 8.1/13
8:15) Oil the inside of the upper tube end toprevent damage to the guide O-ring.
8:16) Fill the correct amount of millilitres oflubricating oil in the tube (refer tablebelow). Before the oil is poured intothe tube, position the tube so that theoil level won’t exceed the hole in thebottom.
8:17) Push in the piston rod with guide intothe tube. Tap down the guide (D)using a hammer and a mandrel.
8:18) Fit the lock ring (C) into the groove inthe tube by pushing one of the lockring ends into the groove, steadying itwith your thumb and then hit on thering until it snaps into the groove. Youcan hear a clicking sound when itfalls into position.
ledoM liO
CM-OSI,CM,MM,M lm2
052TH,052CT lm4
005CT lm8
TH/SMT/MT/ST/CT/UT057
lm01
0051CT/UT lm03
0003CT/UT lm03
0005CT/UT lm04
0057CT/UT lm06
00001CT/UTmm99-52ekorts
lm09
00001CT/UTmm003-001ekorts
lm041
005K lm8
005SKmm94-7,21ekorts
lm5
005SKmm721-05ekorts
lm8
057SK/Kmm94-8ekorts
lm5
057SK/Kmm721-05ekorts
lm01
057BT lm03
0051BT lm04
0003BT lm06
0005BT lm021
8.1/14 SERVICE INSTRUCTION
8:19) Pull out the piston rod (A) and theguide (D) using the T-handle. Pulluntil the guide is in line wih the tubeend. Note! If the guide cannot beplaced in line with the upper end ofthe tube there is something wrongwith the assembly.
Note! Gas should not be put intothe spring until the guide is in linewith the tube end.
8:20) Screw in the valve (K) using the valvetool. The valve should only betightened with finger strength.
8:21a) Fill the spring with gas. See chapter7. Fit the M6 cover screw (J) in thepiston rod. Note that it has a sealingfunction and always must be fittedand tightened on the spring.
8:21b) Fill the spring with gas. See chapter7. Fit the G 1/8" cover screw (J) in thetube and tighten with 15-18 Nm. Notethat it has a sealing function andalways must be fitted and tightenedon the spring.
8:22b) Fit the dirt protection ring (B) so thatit fits in line with the end of the tubeand guide. The function of the dirtprotection ring is to prevent dirt frompenetrating into the gas spring.
Important points to remember
• Never fill any gas spring with more gasthan what is permitted. Maximum pres-sure is 150 bar (15 MPa, 2175 psi). ForM, MM, MC 180 bar (18 Mpa,2610 psi).
• When you have unscrewed the coverscrew: Never lean over the valve.Direct the filling port away from youwhen working with the valve or coverscrew.
• Never use force on the gas spring andprotect the gas spring against damage.High internal pressure.
• Keep the gas springs very clean toachieve the maximum service life.
• All gas springs carry this label (or onsome markets a similar label). This labelmust not be removed or renderedillegible.
Tel. +46 140 571 00, Telefax +
46 140 571 99B
ox 216, SE
-573 23 Tranås Sw
eden
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.
made by
4014
535
SERVICE INSTRUCTION 8.1/15
9. Renovation of CU springs
A) BottomB) Lock ringC) Support ringD) O-ringE) Guide ringF) Piston sealG) Support ringH) Guide ringJ) PistonK) Cover ScrewL) Valve
Category:a) = Model with the valve in the piston rod
b) = Model with the valve in the bottom
Disassembly
9:1a) Clamp the spring with the piston rodupwards in a vice. Clamp at the upperpart of the tube above the C-groove.
Unscrew the M6 cover screw with a3 mm Allen key.
9:1b) Clamp the spring with the bottomupwards in a vice. Fasten at theupper part of the tube, close to thepiston rod.
Unscrew the G 1/8" cover screw (K)with a 5 mm Allen key. If there is nogas left in the spring the bottom (A)may move. If so, gently fasten thetube at its lower end.
b) Valve in the bottom
H
G
F
E
D
C
B
A
K
L
J
a) Valve in the piston rod
G
H
L
KJ
F
E
D
A
B
C
8.1/16 SERVICE INSTRUCTION
9:2) If there is still gas in the spring,release it by screwing the threadedend of the valve tool into the fillingport until the valve needle opens. Thevalve (L) must not be unscrewed untilthe piston rod can be pushed downby hand or be tapped down with aplastic hammer. Then unscrew thevalve with the opposite end of thevalve tool and take the valve out withthe valve pliers.
9:3) Tap down the bottom (A) with a ham-mer and a mandrel until the lock ring(B) is free (for the springs with thevalve in the piston rod, you first turnthe spring upside down). Remove thelock ring with the lock ring tool (thetool with the concave tip). Bend thelock ring upwards and inwards.
9:4a) Turn the tube in upright position, hitthe rod (J) until the bottom (A) comesout of the tube and continue hittinguntil the rod comes out. Sometimesgreat force is required when thesealing lip passes the lock ringgroove.
9:4b) Pull out the bottom (A), using the T-handle. Pour out the oil and press outthe rod (J).
SERVICE INSTRUCTION 8.1/17
9:5) Remove the guide ring (E), thesupport ring (G) and the seal (F) fromthe rod. For dismounting the seal, atool is required to lift it, for instance ascrew driver. Note! Be careful toensure there are no scratches onthe rod, where the seal is placed.
On the smaller models it can bedifficult to lift off the seal by hand. Ifso, lift the seal and cut it loose.
9:6) Remove the guide ring (H) from thetube. Remove the O-ring (D) and thesupport ring (C) from the bottom.
Inspection
9:7) Wash the tube, the rod and the bot-tom.
9:8) Inspect the rod and the inside of thetube to ensure that there are nodefects. There might be scratches inthe tube if the rod has worked withside load. If there are scratchesreplace the parts.
Assembly
9:9) Oil the rod seal (F) gently. Oil theguiding sleeve and slip on the sealwith the black O-ring upwards. (Forsome larger models the seal can beslipped on the rod by hand). Hit orpress on the seal with the plasticmandrel. (The guiding sleeve will getstuck in the plastic mandrel but canbe taken out with a screw driver orsomething similar.) Adjust the O-ringunder the seal ring and push downthe seal.
8.1/18 SERVICE INSTRUCTION
9:10) Fit the guide ring (E) on the pistonand then fit the support ring (G)above the piston seal (F). Note! If thesupport ring is chamfered, the cham-fering should be upwards.
9:11) Fit the support ring (C) and the O-ring (D) on the bottom. The O-ringshould be above the guide ring. Oilthe O-ring before assembly.
9:12) Fit the rod guide (H) by pressing itdown into the tube. If the rod guide isnot divided (only some models),bending it to a kidney shape andpress it down into the tube. The planepart of the lip on the rod guide shouldbe upwards (refer figure below).
9:13) Oil the inside of the tube end with anoily finger and press the rod (J) intothe tube until it stops against the tubestop. The piston rod should then becompletely out. Fill with oil accordingto directions (Refer to table nextpage).
SERVICE INSTRUCTION 8.1/19
9:14) Fit and tap down the bottom (A) untilthe lock ring groove is visible.
9:15) Fit the lock ring (B) into the lock ringgroove by pushing one of the endsinto the groove and then press or hituntil it snaps into the groove. You canhear a clicking sound when it fallsinto position. Older CU 1800 has twolock ring halves that are fitted into thegroove, make sure that both halvesare in the right position.
9:16a) Turn the tube so that the bottom tubeend rests against the bottom of thevice. Fill the tube carefully with com-pressed air through the opening ofthe valve so that the bottom (A) ispressed down into the correctposition, that is, in line with the tubeend.
9:16b) Pull out the bottom (A) using the T-handle until the bottom is in the sameplane as the tube end.
9:17) Check that the lock ring (B) (or insome cases, the lock ring halves) isstill in it’s groove.
Note! Gas must not be filled in thespring until the bottom is in itscorrect position, that is, in linewith the tube end.
9:18) Fit the valve (L) into the filling portwith the valve tool. Note! Fingerstrength is enough to tighten thevalve.
9:19) Fill the spring with the desired gaspressure. Note that the maximumpressure is 150 bar (15 MPa, 2175psi).
9:20a) Fit the M6 cover screw (K) in thepiston rod. Note that it has a sealingfunction and always must be fittedand tightened on the spring.
9:20b) Fit the G 1/8" cover screw (K) in thetube and tighten with 15-18 Nm. Notethat it has a sealing function andalways must be fitted and tightenedon the spring.
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