2
SERVICE INSTRUCTION
Please Note!
Actual gas spring design may appear different from what
shown here.
A)
Piston
B)*
Scraper
C)*
Flex ring
D)*
Piston seal with O-ring
E)
Tube
F)* Valve
G)*
O-ring (& backup ring)
H)
Bottom
I)
Lock ring
J)*
Cover Screw
* = Parts included in
the repair kit.
Differs between
model and version.
Warning!
Always read the permanently marked information on
the side of the tube before service to make sure you
use the correct repair kit. NEVER mix new
components together with old gas spring
components when servicing the spring.
Failure to exhaust all gas pressure prior to disassembling
could result in serious injury.
The maximum charging pressure is 150 bar (2175 psi)
Use only pure nitrogen gas (N
2
) for charging.
Once the cover screw is removed, never lean directly
over the valve. Always direct the valve port away from
yourself and others.
Never use extreme force on the gas spring.
Charged gas springs are under high internal pressure
and should be protected against damage.
Always use protective jaws when clamping the spring in
a vice.
To achieve maximum service life, keep the gas spring
protected from dirt, drawing fluids, and grinding dust.
Always wear protective equipment incl. safety goggles
and rubber gloves, whilst servicing the gas spring in a
well ventilated area. Avoid direct contact with gas spring
lubricants and inhalation of any exhausting gases.
Only specially trained personnel with good knowledge of
the products should carry out the maintenance.
Disassembly
1) To obtain an easy working position, clamp the spring in a
vice (use protective jaws). Unscrew the G1/8" cover
screw (J) with a 5 mm Allen key. If there is no gas left in
the spring, the bottom (H) may rotate. If so, use the
threaded holes at the bottom (H) to prevent the rotation
and unscrew the G1/8"cover screw (J) slightly.
2) If there is still gas pressure in the spring, release it by
screwing the threaded end of the valve tool into the
charging port until the valve needle opens. The valve (F)
must not be unscrewed until the piston can be pushed in
by hand or be tapped in using a plastic mallet. Then
unscrew the valve and remove the valve.
3) Tap in the bottom (H) using a socket and mallet until the
lock ring (I) is exposed. Remove the lock ring with the
lock ring tool. Bend the lock ring upwards and inwards.
4) Pull out the bottom (H), using a T-handle and then pour
out the remaining oil.
5) Clamp the gas spring in the vise with the piston facing
upwards and tap out the piston (A) using socket and
mallet.
6) Remove the piston seal (D) and the Flex ring (C) 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 (B) from the tube.
Note! Replace the scraper (B) with a new one after
each disassembly as it will get damaged while
tapping out the Piston (A), see the figure below.
8) Remove the O-ring (G) and the back-up ring (where
applicable) from the bottom.
Note! Be careful not to damage the overpressure
protection groove while disassembling.
