SERVICE INSTRUCTION
6)
Remove the piston seal (F) and the guide
ring (G) from the piston.
Note! Be careful not to damage the
piston seal groove when removing the
seal.
On smaller models it can be difficult to
remove the seal by hand. If so, lift the seal
and cut it loose using a sharp knife.
7)
Remove the scraper (H) from the tube.
Please note! The same repair kit is used for
all stroke lengths of the CU 1000 and it
should always be repaired from the bottom
as the separate guiding for stroke lengths
32 - 50 mm is not removable.
8)
Next, remove the O-ring (D) and the
support ring (C) from the bottom.
Inspection
9)
Clean the tube, piston and bottom.
10) Closely inspect the inside of the tube and
the sealing grooves on the piston and
bottom. There should be no scratches or
dents on the inside surface of the tube, the
piston or the lock ring grooves. If these
parts are scratched or damaged in any way,
then they should be replaced.
Assembly
11) Unpack the repair kit. Check to make sure
all parts are contained in the kit by
comparing the contents to the picture in
this service instruction. Discard all parts
that are to be replaced with new ones from
the repair kit.
12) First fit the scraper (H) into the top of the
tube. Make sure the scraper sits correctly in
the groove with the lip pointing upwards.
13) Clamp the piston in the vice and mount the
guide ring (G) and the piston seal(F) with
the O-ring facing downwards (nitrogen
side).
14) Mount the support ring (C) and the
O-ring (D) to the bottom. Note! Check that
the O-ring is fitted correctly (nitrogen side) .
Warning! When servicing a PED
designed gas spring, make sure the tube
and bottom are both either marked or
not marked with a circular ring. Do not
mix marked and un-marked
components.
15) Clamp the tube with the lock ring groove
facing upwards securely in the vice. Oil the
seals on the piston and the upper part of
the tube. Fit the piston by pressing it into
the tube and then tapping it down carefully,
using a socket and plastic mallet. Making
sure all of the stroke length becomes
exposed.
16) Fill the spring with the appropriate amount
of oil (see table below).
17) Oil the O-ring (D) on the bottom. Tap down
the bottom (A) into the tube until the lock
ring groove is exposed using the socket
and plastic mallet.
18) Fit the lock ring (B) into the lock ring groove
by pushing one of the ends into the groove,
then either press or hit the other until it
snaps into the groove.
19) Pull out the bottom (A) using the
T-handle until the bottom and the tube are
flush.
Warning! If the bottom and tube are not
flush, the assembly is incorrect. DO NOT
charge the spring. Charging an
incorrectly assembled spring could
result in serious injury.
20) Mount the valve (K) into the charging port
using the valve tool. Tighten only finger
tight. The gas spring is now ready for
charging.
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